Factory Workshop Manual
Make
Chevrolet
Model
Equinox Awd
Engine and year
V6-3.4L (2008)
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This manual was submitted by
Anonymous
Date
1st January 2018
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Accessory Delay Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations > Page 11
Alarm Module: Diagrams
Component Connector End Views - Continued
Theft Deterrent Module (TDM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent Malfunction
Alarm Module: Testing and Inspection Content Theft Deterrent Malfunction
Content Theft Deterrent Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The content theft deterrent (CTD) system is a software based system in which the body control
module (BCM) actively monitors certain inputs to determine if unauthorized vehicle access is being
attempted. Based on inputs such as the door ajar switches, the rear compartment ajar switch, and
the hood ajar switch, the BCM determines whether a CTD alarm is warranted. If unauthorized
access is being detected, the BCM will pulse the vehicle horn and flash the turn signals as a means
of theft deterrence.
Circuit/System Verification
1. Individually open and close each vehicle door while observing the door ajar indicator/message.
The indicator/message should accurately transition
between the door ajar and door closed state when each door is opened and closed.
^ If the door ajar indicator/message does not properly transition when each door is opened and
closed, refer to Door Ajar Indicator Malfunction. See: Body and Frame/Locks/Testing and
Inspection/Symptom Related Diagnostic Procedures/Door Ajar Indicator Malfunction
2. Open and close the liftgate while observing the liftgate ajar indicator/message. The
indicator/message should accurately transition between the
liftgate ajar and liftgate closed state when the trunk is opened and closed.
^ If the liftgate ajar indicator/message does not properly transition when the liftgate is opened and
closed, refer to Liftgate Ajar Indicator Malfunction.
3. Completely lower the driver door window and close all vehicle doors. 4. Ignition OFF, arm the
CTD system using the keyless entry system by pressing the transmitter LOCK button twice. Verify
the scan tool CTD Status
parameter displays Armed.
^ If the parameter does not equal the specified value, refer to Keyless Entry System Inoperative.
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Testing and
Inspection/Symptom Related Diagnostic Procedures/Keyless Entry System Inoperative
5. Without disarming the system, reach in through the open driver window, unlock and open the
driver door. Verify the scan tool CTD Status
parameter displays Alarm Active.
^ If the parameter does not equal the specified value, replace the BCM.
6. With the door open, verify the vehicle horn is pulsing and the exterior lamps are flashing.
^ If the horn is not pulsing, refer to Horns Malfunction. See: Lighting and Horns/Horn/Testing and
Inspection/Symptom Related Diagnostic Procedures/Horns Malfunction
^ If the exterior lights are not flashing, refer to Turn Signal Lamps and/or Indicators Malfunction.
See: Lighting and Horns/Testing and Inspection/Symptom Related Diagnostic Procedures/Turn
Signal Lamps and/or Indicators Malfunction
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent Malfunction >
Page 14
Alarm Module: Testing and Inspection Security Indicator Malfunction
Security Indicator Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The security indicator is controlled by the Body Control Module (BCM) based on commands from
the immobilizer system or the Content Theft Deterrent (CTD) system. With the ignition OFF, the
security indicator is commanded by the CTD system. With the ignition ON, the security indicator is
commanded by the immobilizer system.
The security indicator is located in the Instrument Panel Cluster (IPC) and is supplied B+ at all
times. When the immobilizer or CTD system requests the indicator be commanded ON, the BCM
grounds the security indicator control circuit, illuminating the indicator.
Circuit/System Verification
Ignition ON, command the security indicator ON and OFF with a scan tool. The security indicator
should turn ON and OFF when changing between the commanded states.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the IPC. 2. Connect a test lamp between the
control circuit terminal 16 and B+. 3. Command the security indicator ON and OFF with a scan tool.
The test lamp should turn ON and OFF when changing between the commanded
states.
^ If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the BCM.
^ If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the BCM.
4. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Page 15
Alarm Module: Service and Repair
Theft Deterrent Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations
Central Control Module: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 3 of 3
1 - Instrument Panel Cluster (IPC) 2 - Instrument Panel Trim 3 - Vehicle Communication Interface
Module (VCIM) (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 19
Central Control Module: Diagrams
Component Connector End Views - Continued
Vehicle Communication Interface Module (VCIM) X1 (UE1)
Vehicle Communication Interface Module (VCIM) X2 (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 20
Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Locations > Page 21
Vehicle Communication Interface Module (VCIM) Battery (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Service and Repair > Communication Interface Module Battery
Replacement
Central Control Module: Service and Repair Communication Interface Module Battery Replacement
Communication Interface Module Battery Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Central Control Module > Component Information > Service and Repair > Communication Interface Module Battery
Replacement > Page 24
Central Control Module: Service and Repair Communication Interface Module Replacement
Communication Interface Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 33
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 34
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 >
Campaign - Unwanted Repeat Calls to OnStar(R) > Page 35
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 41
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 42
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 43
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 48
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 54
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 63
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 68
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
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Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 73
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 74
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 80
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position
Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
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Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call >
Page 97
For vehicles repaired under warranty use, the table.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands
Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
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102
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page
103
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 108
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 109
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 110
Method 1
Method 2
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 111
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 129
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 130
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
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Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page 131
Method 1
Method 2
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Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Diagrams
Entertainment System Control Module: Diagrams
Component Connector End Views - Continued
Infrared Transmitter Module (UUC)
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Keyless Entry Module > Component Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
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Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 147
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 148
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D >
Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 149
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 155
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 156
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 157
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: Customer Interest Electrical - No Crank/Start Discharged or Low
Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 173
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control
Module: > 10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/Start Discharged
or Low Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control
Module: > 10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 179
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 180
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 181
Seat Heater Control Module: Diagrams
Component Connector End Views
Heated Seat Control Module X1 (KA1)
Heated Seat Control Module X2 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 182
Heated Seat Control Module X3 (KA1)
Heated Seat Control Module X4 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 183
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 184
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control
Module > Component Information > Technical Service Bulletins > Page 185
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof
Module > Component Information > Diagrams
Sunroof / Moonroof Module: Diagrams
Component Connector End Views - Continued
Sunroof Control Module X1
Sunroof Control Module X2
Transfer Case Shift Control Module - C3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof
Module > Component Information > Diagrams > Page 189
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof
Module > Component Information > Diagrams > Page 190
Sunroof / Moonroof Module: Service and Repair
Sunroof Control Module Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
2. Depress the tab on the side of the control module. 3. With the tab depressed, slide the sunroof
control module toward the sunroof motor. This will release the control module from the sunroof
module.
4. Remove the control module from the sunroof module and disconnect the electrical connector.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof
Module > Component Information > Diagrams > Page 191
1. Connect the electrical connector to the sunroof control module.
2. Insert the control module tabs into the sunroof module slots. 3. Slide the sunroof express module
away from the sunroof motor until it is fully engaged. 4. Verify the proper operation of the sunroof
before securing the headliner. 5. Install the headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay >
Component Information > Locations
Trunk / Liftgate Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 204
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 205
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 206
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 207
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep >
07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep >
07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 213
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 219
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 224
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 225
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 226
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 227
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page
233
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 239
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 240
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 241
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 242
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 243
Electronic Brake Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 244
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 245
Electronic Brake Control Module (EBCM) (Pin 1 To 35)
Electronic Brake Control Module (EBCM) (Pin 36 To 47)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 246
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 247
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams
Control Module HVAC: Diagrams
Component Connector End Views
Blower Motor Control Processor - X1
Blower Motor Control Processor - X2
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 259
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 260
Control Module HVAC: Service and Repair
Blower Motor Control Module Replacement
Removal Procedure
1. Remove Right Lower Insulator Panel 2. Disconnect the electrical connector from the blower
motor control module. 3. Remove the blower control module screws from the HVAC module. 4.
Remove the blower motor control module from the HVAC module.
Installation Procedure
1. Install the blower motor control module to the HVAC module.
Notice: Refer to Fastener Notice.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 261
2. Install the blower motor control module screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the blower motor control module. 4. Install Right Lower
Insulator Panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
08-08-49-017B > Apr > 09 > Instruments - Gauges Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 08-08-49-017B > Apr > 09 > Instruments - Gauges Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Backup Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay
> Component Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay >
Component Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
303
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page
304
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module > Page 311
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module > Page 312
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module > Page 313
Disclaimer
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 314
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Lower Center Instrument Panel Components
1 - Body Control Module (BCM) 2 - Instrument Panel Harness 3 - Center Instrument Panel Support
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 315
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 316
Body Control Module (BCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 317
Body Control Module (BCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 318
Body Control Module (BCM) X4
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 319
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 320
Body Control Module (BCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 321
Body Control Module (BCM) X6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 322
Body Control Module (BCM) X7
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 323
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 324
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important: If data is not retrieved from the malfunctioning body control module (BCM), additional
time will be required to program the replacement BCM.
1. Retrieve data from the malfunctioning BCM. 2. Rotate the ignition switch to the OFF position.
3. Remove the radio bezel. 4. Disconnect the BCM electrical harnesses. 5. Remove the BCM from
the instrument panel (I/P) retainer:
1. Pry the BCM tabs from the locking tabs on the underside of the restraint. 2. Slide the BCM out of
the retainer.
Installation Procedure
1. Install the BCM. 2. Install the radio bezel. 3. Slide the BCM tabs into the slots in the I/P retainer
until the tabs lock into place. 4. Connect the electrical connectors. 5. Program a new or a
remanufactured BCM.
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Electronic Throttle Control Module: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 328
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 1 of 2 (LNJ)
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Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 329
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 330
Electronic Throttle Control Module: Diagrams
Component Connector End Views - Continued
Throttle Actuator Control (TAC) Module (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Engine Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 2 of 2
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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Engine Control Module: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Engine Control Module: Connector Views
Component Connector End Views
Electronic Control Module (ECM) - X1 (LNJ)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 1 To 37)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 38 To 73)
Electronic Control Module (ECM) - X2 (LNJ)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 1 To 36)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 37 To 80)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The engine control module (ECM) interacts with many emission related components and systems,
and monitors the emission related components and systems for deterioration. OBD II diagnostics
monitor the system performance and a diagnostic trouble code (DTC) sets if the system
performance degrades.
The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type.
A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions
related DTC.
The ECM is in the engine compartment. The ECM is the control center of the engine controls
system. The ECM controls the following components:
* The fuel injection system
* The ignition system
* The emission control systems
* The on-board diagnostics
* The A/C and fan systems
* The throttle actuation control (TAC) system
The ECM constantly monitors the information from various sensors and other inputs, and controls
the systems that affect the vehicle performance and the emissions. The ECM also performs
diagnostic tests on various parts of the system. The ECM can recognize operational problems and
alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The
condition area is identified by the particular DTC that is set. This aids the technician in making
repairs.
ECM Function
The engine control module (ECM) can supply 5 volts or 12 volts to the various sensors or switches.
This is done through pull-up resistors to the regulated power supplies within the ECM. In some
cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is
too low. Therefore, a DMM with at least 10 megaohms input impedance is required in order to
ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through the
transistors or a device called an output driver module.
EEPROM
The electronically erasable programmable read only memory (EEPROM) is a permanent memory
that is physically part of the engine control module (ECM). The EEPROM contains program and
calibration information that the ECM needs in order to control the powertrain operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in
order to reprogram the ECM.
Data Link Connector (DLC)
The data link connector (DLC) is a 16-pin connector that provides the technician a means of
accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan
tool in order to monitor the various serial data parameters, and display the DTC information. The
DLC is located inside of the drivers compartment, underneath the dash.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is
controlled by the engine control module (ECM) and illuminates when the ECM detects a condition
that affects the vehicle emissions.
ECM Service Precautions
The engine control module (ECM), by design, can withstand the normal current draws that are
associated with the vehicle operations. However, care must be used in order to avoid overloading
any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the
ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be
tested with a DMM.
Emissions Diagnosis For State I/M Programs
This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive
levels of the following emissions:
* Hydrocarbons (HC)
* Carbon monoxide (CO)
* Oxides of nitrogen (NOx)
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* Evaporative emission (EVAP) system losses
Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in
excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC
that is associated with the condition.
Aftermarket (Add-On) Electrical And Vacuum Equipment
Notice: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on
vacuum equipment may result in damage to vehicle components or systems.
Notice: Connect any add-on electrically operated equipment to the vehicle's electrical system at the
battery (power and ground) in order to prevent damage to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a
vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No
allowances have been made in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the
powertrain system to malfunction. This may also include equipment not connected to the vehicle
electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing
any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle.
After this is done, if the problem still exists, the problem may be diagnosed in the normal manner.
Electrostatic Discharge (ESD) Damage
Important: In order to prevent possible electrostatic discharge damage to the engine control module
(ECM), DO NOT touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very
low voltage. The electronic components are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can cause damage to some electronic
components.
There are several ways for a person to become statically charged. The most common methods of
charging are by friction and by induction. An example of charging by friction is a person sliding
across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly
charged object and momentarily touches ground. Charges of the same polarity are drained off
leaving the person highly charged with the opposite polarity. Static charges can cause damage,
therefore, it is important to use care when handling and testing electronic components.
Emissions Control Information Label
The underhood Vehicle Emissions Control Information Label contains important emission
specifications and setting procedures. In the upper left corner is the exhaust emission information.
This identifies the year, the manufacturing division of the engine, the displacement of the engine in
liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated
emission components and vacuum hose schematic.
This label is located in the engine compartment of every General Motors vehicle. If the label has
been removed, it can be ordered from GM service parts operations (GMSPO).
Underhood Inspection
Important: This inspection is very important and must be done carefully and thoroughly.
Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing
the cause of an emission test failure. This can often lead to repairing a condition without further
steps. Use the following guidelines when performing an inspection:
* Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
* Inspect any hoses that are difficult to see.
* Inspect all of the wires in the engine compartment for the following conditions:
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Notice:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5000 km (3,000 mi) from the last engine oil change.
Important: It is necessary to record the remaining automatic transmission fluid life. If the
replacement module is not programed with the remaining automatic transmission fluid life, the
automatic transmission fluid life will default to 100 percent. If the replacement module is not
programmed with the remaining automatic transmission fluid life, the automatic transmission fluid
will need to be changed at 83000 km (50,000 mi) from the last automatic transmission fluid change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic
transmission fluid life. Record the remaining engine
oil and the remaining automatic transmission fluid life.
2. Slide the engine control module (ECM) retainer rearward, disengaging the retainer from the
battery shield. 3. Remove the ECM retainer from the top of the battery shield.
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4. Remove the ECM from the retainer. Reposition the ECM out of the way.
5. Disconnect the negative battery cable. 6. Place the battery shield over the battery. 7. Place the
ECM on top of the battery shield. 8. Disconnect the engine wiring harness electrical connectors (2)
from the ECM.
Installation Procedure
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1. Connect the engine wiring harness electrical connectors (2) to the ECM. Reposition the ECM out
of the way. 2. Remove the battery shield from over the battery. 3. Connect the negative battery
cable.
4. Install the ECM to the retainer.
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5. Position the ECM and retainer to the top of the battery shield. 6. Slide the ECM retainer
rearward, engaging the retainer to the battery shield.
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Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuel Pump Relay: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 543
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 544
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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and Instructions > Page 545
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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and Instructions > Page 547
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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and Instructions > Page 548
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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and Instructions > Page 550
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 551
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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and Instructions > Page 552
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 555
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 556
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 557
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 558
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 559
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 2 of 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 567
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 568
Ignition Control Module: Diagrams
Component Connector End Views
Ignition Control Module (ICM) (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement
Ignition Control Module: Service and Repair Ignition Coil/Control Module Replacement
Ignition Coil/Control Module Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
spark plug wires. Note the position from which the wires are removed. 4. Disconnect the ignition
coil/control module electrical connectors. 5. Remove the 4 bolts securing the ignition coil/control
module to the ignition control module bracket. 6. Remove the ignition coil/control module.
Installation Procedure
1. Install the ignition coil/control module to the ignition control module bracket.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 571
2. Install the 4 bolts securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
3. Connect the ignition coil/control module electrical connectors. 4. Connect the spark plug wires. 5.
Install the injector sight shield. 6. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 572
Ignition Control Module: Service and Repair Ignition Control Module Bracket Replacement
Ignition Control Module Bracket Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
ignition coil/control module electrical connectors. 4. Remove the spark plug wire retainer (1) from
the ignition control module bracket. 5. Remove the 4 bolts securing the ignition coil/control module
to the ignition control module bracket. 6. Position the ignition coil/control module aside out of the
way. 7. Remove the bolt (3) from the fuel injector wire harness bracket (4) and positive crankcase
ventilation (PCV) valve fresh air tube retainer. 8. Remove the engine wire harness retainers from
the ignition control module bracket studs (5).
9. Remove the nut (1) retaining the heater outlet pipe.
10. Lift pipe up slightly to gain access for the removal of the 2 ignition control module bracket bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 573
11. Remove the ignition control module bracket bolts (2). 12. Remove the ignition control module
bracket nuts (6). 13. Remove the ignition control module bracket.
Installation Procedure
1. Install the ignition control module bracket.
Notice: Refer to Fastener Notice.
2. Install the ignition control module bracket nuts (6).
Tighten the nuts to 25 N.m (18 lb ft).
3. Install the ignition control module bracket bolts (2).
Tighten the bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 574
4. Install the nut (1) retaining the heater outlet pipe.
Tighten the nut to 25 N.m (18 lb ft).
5. Install the engine wire harness retainers to the ignition control module bracket studs (5). 6. Install
the bolt (3) from the fuel injector wire harness bracket (4) and PCV valve fresh air tube retainer.
Tighten the bolts to 5 N.m (44 lb in).
7. Install the ignition coil/control module to the ignition control module bracket. 8. Install the 4 bolts
securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
9. Install the spark plug wire retainer (1) to the ignition control module bracket.
10. Connect the ignition coil/control module electrical connectors. 11. Install the injector sight
shield. 12. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Relay > Component Information > Locations
Ignition Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 587
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 588
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D >
Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set
Air Bag Control Module: Customer Interest Restraints - Airbag Light On/DTC B0081 Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D >
Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set > Page 593
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC
Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 599
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 600
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
06-09-41-006D > Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Airbag Light On/DTC B0081
Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
06-09-41-006D > Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set > Page 605
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 606
Air Bag Control Module: Locations
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 607
Air Bag Control Module: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Sensing and Diagnostic Module (SDM) (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 608
Inflatable Restraint Sensing and Diagnostic Module (SDM) (-ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 609
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 610
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 611
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 612
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Seat
Occupant Classification Module - Air Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: Customer Interest Restraints - AIr Bag Lamp
ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Seat Occupant Classification Module - Air Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Restraints - AIr Bag
Lamp ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 640
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 641
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 642
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 643
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: Customer Interest Steering/Suspension - Noise/Looseness In Steering
Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 653
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In
Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 663
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 668
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 669
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 670
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 671
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering
Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 681
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
687
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
688
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
689
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
690
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 691
Steering Control Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 692
Steering Control Module: Diagrams
Component Connector End Views - Continued
Power Steering Control Module (PSCM) X1
Power Steering Control Module (PSCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 693
Power Steering Control Module (PSCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 694
Power Steering Control Module (PSCM) X4
Power Steering Control Module (PSCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 695
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 696
Steering Control Module: Service and Repair
Electronic Power Steering Motor Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tire Monitor System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 711
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 712
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 713
Transmission Control Module (TCM) X3 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Page 714
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 717
7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 718
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 719
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 720
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Powertrain
Management/Computers and Control Systems/Sensors and Switches - Computers and Control
Systems/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 721
1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 722
5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Powertrain
Management/Computers and Control Systems/Sensors and Switches - Computers and Control
Systems/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 723
Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with the correct software and calibrations, DTC P0602 will be
erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Transmission
and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/AF33-5 - Automatic Transaxle/Transmission Adaptive Learn and
Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Differential > Control Unit, Differential Lock > Component Information > Service and Repair > Rear Differential
Clutch Control Module Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Differential > Control Unit, Differential Lock > Component Information > Service and Repair > Rear Differential
Clutch Control Module Replacement > Page 729
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations
Windshield Washer Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Sensor > Component Information > Locations > Page 745
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering
Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Steering Mounted Controls Assembly > Component Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement (Equinox)
Removal Procedure
1. Use a small flat-bladed tool to release the switch assembly from the steering wheel. 2.
Disconnect the cruise switch electrical harness connector from the switch.
Installation Procedure
1. Connect the switch electrical harness connector to the switch. Push in the connector until a click
is heard and pull back to confirm a positive
engagement.
2. Insert the cruise switch into the steering wheel and gently apply pressure to fasten the switch in
the opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor
> Hood Sensor/Switch (For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Sensor > Component Information > Locations > Page 761
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations
Power Door Lock Switch: Locations
Door Component Views
Driver Door Components
1 - Outside Rearview Mirror - Driver 2 - Window Motor - Driver 3 - Door Lock Switch - Driver 4 Door Latch - Driver
Passenger Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 765
1 - Door Latch - Front Passenger 2 - Door Lock Switch - Front Passenger 3 - Window Motor - Front
Passenger 4 - Outside Rearview Mirror - Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 766
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock Switch - Driver
Door Lock Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 767
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock
Switch > Component Information > Locations > Page 768
Power Door Lock Switch: Service and Repair
Door Lock Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Power Mirror Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 772
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 773
Power Mirror Switch: Diagrams
Component Connector End Views - Continued
Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 774
Power Mirror Switch: Service and Repair
Power Mirror Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views
Power Seat Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Power Driver Seat Components
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 779
Power Seat Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 780
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 781
Power Seat Switch: Diagrams
Component Connector End Views - Continued
Seat Adjuster Switch Driver
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Power Seat Switch: Service and Repair Driver Seat and Passenger Seat Adjuster Switch Knob
Replacement
Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement >
Page 784
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement >
Page 785
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Seat Heater Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 789
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front Headliner Components
1 - Dome Lamp - Center (-UUC) 2 - Cellular Telephone Microphone (UE1) 3 - Sunroof Switch
(CF5) 4 - Courtesy / Map Lamp
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 793
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views - Continued
Sunroof Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 794
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Removal Procedure
1. Pull gently at front of reading lamp cover to disengage retaining clips. 2. Rotate cover rearward
until rear attaching hooks are released. 3. Disconnect sunroof switch harness from sunroof switch.
4. Remove sunroof switch fasteners and remove sunroof switch.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Page 795
1. Install sunroof switch with fasteners.
Tighten sunroof switch to 2.5 N.m (22 lb in)
2. Connect sunroof switch harness to sunroof switch. 3. Position front reading lamp cover into rear
attaching hooks. 4. Rotate front reading lamp cover into lamp assembly forward, then snap cover
into place. 5. Function sunroof switch to ensure proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch
> Component Information > Diagrams
Trunk / Liftgate Switch: Diagrams
Component Connector End Views - Continued
Liftgate Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 803
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 804
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Disconnect the brake fluid level indicator switch electrical
connector.
3. While simultaneously depressing the retaining tabs on the opposite side of the switch electrical
connection, carefully pull the switch from the
master cylinder reservoir.
4. Remove the low brake fluid level sensor.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 805
1. While noting the proper orientation, install the brake fluid level indicator switch to the master
cylinder. 2. Press the brake fluid level indicator switch firmly into the master cylinder reservoir,
ensuring that the retaining tabs are fully engaged.
3. Connect the brake fluid level indicator switch electrical connector. 4. Install the underhood
electrical center bracket. Refer to Underhood Electrical Center or Junction Block Bracket
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations
Parking Brake Release Switch: Locations
Passenger Compartment/Roof Component Views
Park Brake Assembly Components
1 - Park Brake Switch 2 - Park Brake Handle 3 - Floor Panel
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Page 809
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Angle Sensor Centering
The steering angle sensor does not require centering often. Centering of the steering angle sensor
might be required after certain service procedures are performed. Some of these procedures are
as follows:
* Steering gear replacement
* Steering column replacement
* Steering angle sensor replacement
* Intermediate shaft replacement
* Antilock brake system (ABS) controller replacement
* Collision or other physical damage
The steering angle sensor centering procedure can be preformed with a scan tool in the automated
center procedure by the following:
1. Using the steering wheel, align the front wheels forward. 2. Set the transmission in the PARK
position. 3. Install the scan tool to the data link connector (DLC). 4. Turn the ignition switch ON,
with the engine OFF. 5. Select Chassis/EBCM control system vehicle stability enhancement
system (VSES), special function test, and Steering Pos. Sensor Calibration. 6. Follow the scan tool
directions to complete the automated centering procedure this should include turning the steering
wheel left 5 degrees and
right 5 degrees and then straight forward.
7. Clear any DTCs that may be set. Perform the Diagnostic System Check to verify no current
DTCs. Refer to Diagnostic System Check - Vehicle . 8. Centering of the steering angle sensor is
complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
Traction Control Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 819
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 820
Traction Control Switch: Diagrams
Component Connector End Views - Continued
Traction Control Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 821
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
2. Carefully release the retaining tabs and remove the traction control switch from the trim bezel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 822
1. Install the traction control switch to the trim bezel. Ensure that the retaining tabs are fully
engaged.
2. Install the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Left Front Suspension Components
1 - X103 Left Shown, X104 Right Similar 2 - Wheel Speed Sensor (WSS) - Left Front, Right Front
Similar
Rear Axle Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 826
1 - Rear Cradle 2 - Wheel Speed Sensor (WSS) - Left Rear 3 - Wheel Speed Sensor (WSS) - Right
Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 827
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 828
Wheel Speed Sensor - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Page 829
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 832
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 836
Yaw Rate Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 837
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 843
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 844
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 845
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 846
Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
Notice: Improper cruise control release switch adjustment may cause brake damage such as brake
drag, heat buildup and excessive brake lining wear.
3. Disconnect the cruise brake switch harness connector. 4. Rotate the cruise brake switch
counterclockwise and remove the cruise brake switch from the switch retainer.
Important: Do not depress the brake pedal assembly during the brake switch installation.
Depressing the brake pedal will cause a brake drag condition.
5. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 851
6. Connect the cruise brake switch harness connector. 7. Install the knee bolster. 8. Install the
instrument panel left lower closeout panel. 9. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 852
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
3. Disconnect the cruise brake switch connector.
4. Rotate the cruise brake switch counterclockwise and remove the cruise brake switch from the
switch retainer.
Important: Depressing the brake pedal will allow easier access of the retainer locking tabs.
5. Gently compress the locking tabs on the cruise brake retainer and remove the switch retainer
from the brake pedal assembly.
Installation Procedure
Important: Ensure that the indexing arrow is facing to the right and the ears on the retainer are fully
extended on the back side of the bracket to prevent the retainer from being pushed out.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 853
1. Install the cruise brake switch retainer into the upper hole of the brake pedal assembly with the
retainer arrow pointing in the 3 o'clock position.
Important: Do not depress the brake pedal assembly during the cruise brake switch installation.
Depressing the brake pedal during the cruise brake switch installation will cause a brake drag
condition.
2. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 854
3. Connect the cruise brake switch harness connector. 4. Install the knee bolster. 5. Install the
instrument panel left lower closeout panel. 6. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Locations > Page 859
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure Switch (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor >
Component Information > Service and Repair > Page 863
1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for
the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front of Vehicle/Engine Compartment Component Views
Behind the Front Fascia Components
1 - Headlamp - Right 2 - Radiator 3 - Ambient Air Temperature Sensor (DH3/DF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 868
Ambient Temperature Sensor / Switch HVAC: Diagrams
Component Connector End Views
Ambient Air Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 869
Ambient Temperature Sensor / Switch HVAC: Service and Repair
Ambient Air Temperature Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
Instrument Panel/Center Console Component Views
Front HVAC Module Components
1 - Recirculation Actuator 2 - HVAC Blower Motor 3 - Blower Motor Control Processor 4 - Air
Temperature Actuator 5 - Mode Actuator 6 - Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations > Page 873
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair
Low Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Low Temperature Sensor Replacement
Removal Procedure
1. Remove the left side insulator/closeout panel. 2. If equipped with OnStar(R), remove the
communications interface module. 3. Disconnect the temperature sensor connector from the
temperature sensor. 4. Twist the temperature sensor one quarter turn to disengage from the
evaporator case assembly. 5. Remove the temperature sensor from the evaporator case assembly.
Installation Procedure
1. Install the temperature sensor to the evaporator case assembly. 2. Twist the temperature sensor
one quarter turn to engage to the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Page 878
3. Install the temperature sensor connector to the temperature sensor. 4. If removed, install the
communications interface module. 5. Install the left side insulator/closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations
Dimmer Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 883
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 884
Dimmer Switch: Diagrams
Component Connector End Views
Dimmer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 885
Dimmer Switch: Service and Repair
Instrument Panel Lamp Dimmer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 894
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 895
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 896
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 897
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 898
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel
Sender Harness Modification > Page 899
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 905
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 906
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 907
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 908
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 909
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 >
Jan > 08 > Recall - Fuel Sender Harness Modification > Page 910
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Page 911
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake
Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations
Ambient Light Sensor: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 919
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 920
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light
Sensor > Component Information > Locations > Page 921
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Service and Repair > Brake Pedal Position Sensor Calibration
Brake Light Switch: Service and Repair Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Calibration
Calibration Criteria
The brake pedal position sensor (BPPS) receives a low reference signal and a 5-volt reference
signal from the BCM. Whenever the brake pedal is applied, the BPPS applies a variable voltage
signal to the BCM through the stop lamp switch signal circuit. The BPPS calibration must be
performed after the BPPS or body control module (BCM) have been serviced. The calibration
procedure will set BPPS home value. This value is used by the BCM to determine the action of the
driver applying the brake system and to provide this information to the vehicle subsystems via the
communication bus.
Calibration Procedure
* Install a scan tool.
* Turn ON the ignition, with the engine OFF.
* Select Diagnostics.
* Select the year.
* Select the vehicle type.
* Select BCM.
* Select Module Setup.
* Select the BPPS calibration procedure and follow the directions displayed on the screen.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 926
Brake Light Switch: Service and Repair Brake Pedal Position Sensor Replacement
Brake Pedal Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations > Page 930
Combination Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch
> Component Information > Locations > Page 931
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch
> Component Information > Diagrams
Dome Lamp Switch: Diagrams
Component Connector End Views - Continued
Vanity Mirror Dome Lamp Switch (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations
Fog/Driving Lamp Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 938
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 939
Fog/Driving Lamp Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 940
Fog/Driving Lamp Switch: Service and Repair
Fog Lamp Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations
Hazard Warning Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 944
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 945
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning
Switch > Component Information > Locations > Page 946
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
Horn Switch: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Horn Switch 2 - Steering Wheel Control Switch - Right (UK3/K34) 3 - Steering Wheel Control
Switch - Left (UK3/K34)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations > Page 950
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 954
Turn Signal Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 955
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 958
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
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Page 964
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Page 965
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 972
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 1059
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 1062
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 1063
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1064
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1066
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1067
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1068
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Information and Instructions > Page 1069
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Information and Instructions > Page 1070
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
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Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
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1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
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Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 1084
Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 1085
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Information and Instructions > Page 1086
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1176
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1180
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Information and Instructions > Page 1181
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Information and Instructions > Page 1182
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
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Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
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Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 1286
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 1287
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 1288
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1289
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 1290
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1291
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1292
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1293
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Information and Instructions > Page 1294
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Information and Instructions > Page 1295
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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Crankshaft Position Sensor Replacement > Page 1298
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Level Sensor Replacement - Secondary
Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - Secondary
Fuel Level Sensor Replacement - Secondary
Removal Procedure
Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced.
Obtain a NEW seal prior to beginning this service procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and the float electrical connector. 4. Release the retaining tabs and remove the level sensor by
sliding up.
Installation Procedure
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1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place. 2. Connect the fuel level sender unit and the float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Level Sensor Replacement - Secondary > Page 1306
Fuel Level Sensor: Service and Repair Primary Fuel Level Sensor Replacement
Primary Fuel Level Sensor Replacement
Removal Procedure
Important: NEW fuel tank module seals are necessary each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and secondary modules prior to beginning this service
procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and float electrical connector from the underside of the top of the pump module. 4. Release the
retaining tabs (1, 2) and remove the level sensor by sliding up.
Installation Procedure
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Level Sensor Replacement - Secondary > Page 1307
1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place (1, 2). 2. Connect the fuel level sender unit and float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Fuel Tank Pressure Sensor: Locations
Wheels/Vehicle Underbody Component Views
Rear Axle and Fuel Tank Components
Near The Rear Differential
1 - Rear Differential Clutch Control Module (MH6) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP)
Canister Vent Solenoid 4 - Fuel Sending Unit 5 - Fuel Tank Pressure (FTP) Sensor
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1311
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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1312
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Remove the fuel tank.
2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure
sensor.
3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4.
Carefully use the screwdrivers to lift and release the sensor from the fuel pump module.
Installation Procedure
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1313
1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor
grommet is fully seated to the pump module.
2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel
tank.
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
Intake Air Temperature Sensor: Specifications
Temperature Versus Resistance
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Page 1317
Intake Air Temperature Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Page 1318
Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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and Instructions > Page 1337
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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and Instructions > Page 1418
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 1419
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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and Instructions > Page 1420
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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and Instructions > Page 1421
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1422
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1423
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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and Instructions > Page 1424
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
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and Instructions > Page 1425
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Sensor Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
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Sensor Replacement - Bank 1 > Page 1429
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
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Sensor Replacement - Bank 1 > Page 1430
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
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Sensor Replacement - Bank 1 > Page 1431
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
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Sensor Replacement - Bank 1 > Page 1432
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Page 1436
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LNJ)
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Page 1437
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
2. Remove the MAP sensor retaining bolt (3) and bracket (2). 3. Remove the MAP sensor (1) and
the MAP sensor port seal if it is still retained in the intake manifold.
Installation Procedure
1. Install the MAP sensor (1) to the intake manifold.
Notice: Refer to Fastener Notice.
2. Install the MAP sensor retaining bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
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Page 1438
3. Connect the MAP sensor electrical connector.
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Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
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1442
1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for
the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Exhaust Components (LNJ)
1 - Heated Oxygen Sensor (HO2S) 1 2 - Heated Oxygen Sensor (HO2S) 2
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Oxygen Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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and Instructions > Page 1519
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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and Instructions > Page 1521
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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and Instructions > Page 1523
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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and Instructions > Page 1524
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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and Instructions > Page 1525
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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and Instructions > Page 1527
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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and Instructions > Page 1528
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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and Instructions > Page 1537
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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and Instructions > Page 1538
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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and Instructions > Page 1539
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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and Instructions > Page 1540
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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and Instructions > Page 1541
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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and Instructions > Page 1543
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 1544
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1545
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and Instructions > Page 1546
Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LNJ)
Heated Oxygen Sensor (HO2S) 2 (LNJ)
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and Instructions > Page 1547
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Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Oxygen and Oxygen Sensor Notice > Page 1550
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
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Oxygen and Oxygen Sensor Notice > Page 1551
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
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Oxygen and Oxygen Sensor Notice > Page 1552
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
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Oxygen and Oxygen Sensor Notice > Page 1553
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
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Oxygen and Oxygen Sensor Notice > Page 1554
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
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Oxygen Sensor 1 Replacement
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 1 Replacement
Heated Oxygen Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector from the heated oxygen sensor (HO2S). 3. Remove the HO2S from the
exhaust manifold.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
1. Apply a small amount of anti-seize compound to the threads of the HO2S.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S to the exhaust manifold.
Tighten the HO2S to 42 N.m (31 lb ft).
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Oxygen Sensor 1 Replacement > Page 1557
3. Connect the engine wiring harness electrical connector to the HO2S. Push in the connector until
a click is heard and pull back to confirm a positive
engagement.
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Oxygen Sensor 1 Replacement > Page 1558
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 Replacement
Heated Oxygen Sensor 2 Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the HO2S 2 harness connector (3).
Important: Silicone based products will contaminate the HO2S. DO NOT use products containing
silicone on or near the HO2S.
3. Use a liquid penetrate before removing the sensor. 4. Remove the HO2S 2 (2) from the exhaust
pipe.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
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1. Apply a small amount of anti-seize compound to the threads of the HO2S 2.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S 2 (2).
Tighten the HO2S 2 to 42 N.m (31 lb ft).
3. Connect the HO2S 2 harness connector (3). Push in the connector until a click is heard, then pull
back to confirm a positive engagement. 4. Ensure the HO2S 2 harness pigtail connector is secure
to the chassis.
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 1565
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Information and Instructions > Page 1566
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 1650
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 1651
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 1652
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 1653
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 1654
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 1655
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1656
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 1657
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1658
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1659
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1660
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1661
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Automatic Transmission Electronic Component Views > Page 1666
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
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Locations > Automatic Transmission Electronic Component Views > Page 1667
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Automatic Transmission Electronic Component Views > Page 1668
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
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Service and Repair > 6T70/6T75 - Automatic Transmission > Page 1671
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
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Service and Repair > 6T70/6T75 - Automatic Transmission > Page 1672
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
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Page 1677
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Page 1678
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
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Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 1772
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 1775
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 1776
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 1777
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 1778
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 1779
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 1780
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 1781
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 1782
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Information and Instructions > Page 1783
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 1790
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 1791
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Information and Instructions > Page 1792
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 1976
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Instructions > Page 1977
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Instructions > Page 1978
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Instructions > Page 1979
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Instructions > Page 1980
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 1981
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Instructions > Page 1982
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Instructions > Page 1983
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 1984
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 1985
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 1986
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 1987
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 2096
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Instructions > Page 2097
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Instructions > Page 2098
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
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Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To
Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key
Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
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> Procedures > Page 2119
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
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> Procedures > Page 2120
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
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> Procedures > Page 2121
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
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> Procedures > Page 2122
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 2123
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 2124
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2128
Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2129
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Page 2132
Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Page 2133
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Page 2134
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Page 2135
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Page 2136
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Page 2137
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Page 2215
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Page 2219
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Page 2221
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Page 2223
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Page 2224
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Page 2225
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 2226
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Page 2227
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2228
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2229
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2230
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2231
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2232
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 2235
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 2236
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 2237
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 2238
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Passenger Compartment/Roof Component Views
Impact Sensor: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 2244
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Core Support Components
1 - Inflatable Restraint Front End Sensor - Left 2 - Radiator Core Support 3 - Cooling Fan - Right 4
- Cooling Fan - Left
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 2245
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left (-ASF)
Inflatable Restraint Front End Sensor - Right (-ASF)
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 2246
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Rollover Sensor
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 2247
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 2250
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 2251
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 2252
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations
Seat Belt Buckle Switch: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Power Driver Seat Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2256
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2257
Seat Belt Buckle Switch: Diagrams
Component Connector End Views - Continued
Seat Belt Switch - Left
A/T Shift Lock Control Solenoid
Seat Belt Switch - Right
A/T Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 2262
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant
Sensor > Component Information > Technical Service Bulletins > Page 2263
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2268
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2269
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 2270
1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2287
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2288
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2289
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2290
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2291
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 2292
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2307
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2308
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2309
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2310
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 2311
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2312
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service
and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
*
When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2313
Notice: Refer to Fastener Notice .
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and
Repair) .
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Sensor Learn
(Standard) (See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 2319
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations > Page 2323
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 2331
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 2332
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 2333
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 2336
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 2337
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2342
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2343
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2344
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2345
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2346
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic
Transaxle > Page 2347
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2348
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2349
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 2350
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission > Page 2353
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission > Page 2354
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission > Page 2355
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission > Page 2356
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 Automatic Transmission > Page 2357
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 2363
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 2364
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 2365
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2366
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Instrument Panel/Center Console Component Views
Power Window Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2372
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2373
Power Window Switch: Locations Door Component Views
Door Component Views
Left Rear Door Components
1 - Door Latch - Left Rear 2 - Window Switch - Left Rear 3 - Window Motor - Left Rear
Right Rear Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Instrument Panel/Center Console Component Views > Page 2374
1 - Window Switch - Right Rear 2 - Door Latch - Right Rear 3 - Window Motor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 2375
Power Window Switch: Diagrams
Component Connector End Views - Continued
Power Window Switch - Main X1
Power Window Switch - Main X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 2376
Window Switch - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 2377
Window Switch - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Page 2378
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement
Front Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 2381
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2386
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2387
Windshield Washer Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2388
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement
Windshield Washer Switch: Service and Repair Rear Window Wiper and Washer Switch
Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement >
Page 2391
Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch
Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement >
Page 2392
2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 2396
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 2397
Wiper Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 2398
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement
Wiper Switch: Service and Repair Rear Window Wiper and Washer Switch Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page
2401
Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page
2402
2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications
Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications
WARRANTY ADMINISTRATION
Bulletin No.: 05-03-07-009C
Date: December 09, 2010
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks
Supercede: This bulletin is being extensively revised to provide technicians and warranty
administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF
WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT
SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension).
Purpose
The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors'
warranty service requirements and recommendations for customer concerns related to wheel
alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel
Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty
service.
Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING
YOUR NEXT GM WHEEL ALIGNMENT SERVICE.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a
successful wheel alignment service.
1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension
and steering configurations. Vehicles
modified in any of these areas are not covered for wheel alignment warranty.
2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is
within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for
labor operations E2000 and E2020.
The following information must be documented or attached to the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the
appropriate calibration maintenance schedules.
Important If it is determined that a wheel alignment is necessary under warranty, use the proper
labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel
Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for
other component repairs is to be charged to the component that causes a wheel alignment
operation.).
The following flowchart is to help summarize the information detailed in this bulletin and should be
used whenever a wheel alignment is performed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2408
Verify Original Equipment Condition of the Vehicle
- Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are
on the vehicle.
- Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have
NOT been done to the vehicle.
- Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision
damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles,
suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact.
- Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving
may show up by looking at the tires and condition of the vehicle.
- Check for other additional equipment items that may significantly affect vehicle mass such as
large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in
trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and
wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed
semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of
these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with
equipment such as the above.)
Customer Concerns, "Normal Operation" Conditions and "Mileage Policy"
Possible Concerns
The following are typical conditions that may require wheel alignment warranty service:
1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of
effort required at the steering wheel to maintain the
vehicle's straight heading."
Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle
Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull
concerns can be due to road crown or road slope, tires, wheel alignment or even in rare
circumstances a steering gear issue. Lead/pull concerns due to road crown are considered
"Normal Operation" and are NOT a warrantable condition -- the customer should be advised that
this is "Normal Operation."
Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a
level condition. If so, this is more likely a "steering wheel angle" concern because the customer is
"steering" the vehicle to obtain a "level" steering wheel.
2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined
as the steering wheel angle (clocking)
deviation from "level" while maintaining a straight heading on a typical straight road.
3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the
shoulders of tires is NOT considered unusual and
should even out with a tire rotation; if the customer is concerned about a "feathering" condition of
the tires, the customer could be advised to rotate the tires earlier than the next scheduled
mileage/maintenance interval (but no later than the next interval). Be sure to understand the
customer's driving habits as this will also heavily influence the tire wear performance; tire wear from
aggressive or abusive driving habits is NOT a warrantable condition.
Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is
"normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can
show evidence of feathering from the factory. These issues do NOT affect the overall performance
and tread life of the tire. Dealer personnel should always check the customer's maintenance
records to ensure that tire inflation pressure is being maintained to placard and that the tires are
being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be
performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications > Page 2409
Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center
Ribs
Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder
Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear
Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear
Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the
repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center
wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF,
LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life,
etc. A field product report with pictures of the tire wear condition is recommended. Refer to
Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C.
4. Other repairs that affect wheel alignment; e.g., certain component replacement such as
suspension control arm replacement, engine cradle
adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock,
steering knuckle, etc. may require a wheel alignment.
Important If other components or repairs are identified as affecting the wheel alignment, policy calls
for the wheel alignment labor time to be charged to the replaced/repaired component's labor
operation time rather than the wheel alignment labor operations.
Important Vibration type customer concerns are generally NOT due to wheel alignment except in
the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are
NOT to be performed as an investigation/correction for vibration concerns.
"Normal Operation" Conditions
Vehicle Lead/Pull Due to Road Crown or Slope:
As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope.
Be sure to verify from the customer the types of roads they are driving as they may not recognize
the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires
significant steering effort to prevent it from "climbing" the road crown there may be an issue to be
looked into further.
Important
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A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within
"Normal Operation."
Mileage Policy
The following mileage policy applies for E2020 and E2000 labor operations: Note
Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana
Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing
the vehicles.
- 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to
the tie down during shipping, the vehicle's suspension requires some time to reach normal
operating position. For this reason, new vehicles are generally NOT to be aligned until they have
accumulated at least 800 km (500 mi). A field product report should accompany any claim within
this mileage range.
- 801-12,000 km (501-7,500 mi):
- If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle
steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be
apparent early in the life of the vehicle. The following policy applies:
- Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT,
Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and
Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required
- All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above:
E2000/E2020 Claims: Dealer Service Manager Authorization Required
- 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible
for the wheel alignment expense or dealers may provide on a case-by case basis a one-time
customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component
required the use of the subject labor operations, the identified defective component labor operation
will include the appropriate labor time for a wheel alignment as an add condition to the component
repair.
Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN.
Warranty Documentation Requirements
When a wheel alignment service has been deemed necessary, the following items will need to be
clearly documented on/with the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
1. Document the customer concern in as much detail as possible on the repair order and in the
warranty administration system. Preferred examples:
- Steering wheel is off angle in the counterclockwise direction by approximately x degrees or
clocking position.
- Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe,
Moderate or Slight.
- RF and LF tires are wearing on the outside shoulders with severe feathering.
Important In the event of a lead/pull or steering wheel angle concern, please note the direction of
lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the
repair order and within the warranty claim verbatim.
Important In the event of a tire wear concern, please note the position on the vehicle and where the
wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder.
2. Document the technician's findings on cause and correction of the issue. Examples:
- Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees
to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees.
- Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of
+0.30 degrees to 0.00 degrees on the vehicle.
- Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees.
3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the
Repair Order or if print-out capability is not
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available, measurements may also be clearly and legibly handwritten into the Wheel Alignment
Repair Order Questionnaire attached to this bulletin.
4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of
"Before" and "After" wheel alignment measurements to
the Repair Order and retain for use by GM.
Wheel Alignment Equipment and Process
Wheel alignments must be performed with a quality machine that will give accurate results when
performing checks. "External Reference" (image-based camera technology) is preferred. Please
refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment
Requirements and Recommendations.
Requirements:
- Computerized four wheel alignment system.
- Computer capable of printing before and after alignment reports.
- Computer capable of time and date stamp printout.
- Racking system must have jacking capability
- Racking system must be capable of level to 1.6 mm (1/16 in)
- Appropriate wheel stops and safety certification
- Built-in turn plates and slip plates
- Wheel clamps capable of attaching to 20" or larger wheels
- Racking capable of accepting any GM passenger car or light duty truck
- Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations:
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration:
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
- Alignment machines with "internal reference" sensors should be checked (and calibrated, if
necessary) every six months.
- Alignment machines with "external reference" (image-based camera technology) should be
checked (and calibrated, if necessary) once a year.
- Racks must be kept level to within 1.6 mm (1/16 in).
- If any instrument that is part of the alignment machine is dropped or damaged in some way,
check the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Wheel Alignment Process
When performing wheel alignment measurement and/or adjustment, the following steps should be
taken:
Preliminary Steps:
1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels
and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4.
Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for
looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to
stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate
for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's
instructions.
Measure/Adjust:
Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify
that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date
by comparing these to the wheel alignment specifications for the appropriate model and model year
in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments,
irregular and/or premature tire wear and repeat customer concerns
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Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
If necessary, adjust the wheel alignment to vehicle specification and record the before and after
measurements. Refer to Wheel Alignment Specifications in SI.
Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only
source of GM wheel alignment specifications that is kept up-to-date throughout the year.
Test drive vehicle to ensure proper repair.
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Frame Angle Measurement (Express / Savana Only) ........
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What corrected the customer concern and was the repair verified?
Please Explain: .............
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Fastener Tightening
Specifications
Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications
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Alignment: Specifications Trim Height Specifications
Trim Height Specifications
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Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications
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Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster
Description
Alignment: Description and Operation Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
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Alignment: Description and Operation Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
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Alignment: Description and Operation Toe Description
Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
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Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
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Alignment: Description and Operation
Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
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Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
Thrust Angles Description
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
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If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be
centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel
alignment.
Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle.
Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle.
If the thrust angle is out of specification, moving the axle to body relationship will change the thrust
angle reading.
If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will
move the thrust angle towards zero degrees.
If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will
move the thrust angle towards zero degrees.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Torque Steer Description
Torque Steer Description
A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the
other direction during deceleration.
The following factors may cause torque steer to be more apparent on a particular vehicle:
* A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front
tires for differences in the brand, the construction, or the size. If the tires appear to be similar,
change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the
most significant effect on torque steer correction.
* A large difference in the right and left front tire pressure
* Left-to-right differences in the front view axle angle may cause significant steering pull in a
vehicle. The pull will be to the side with the most downward sloping axle from the differential to the
wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to
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level ground may be used as an indication of bias axle angles. The side with the higher transaxle
pan (shown on the left side of the illustration) has the most downward sloping axle angle.
Memory Steer Description
Memory Steer Description
Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned
the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in
that direction.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
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Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurement
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause the vehicle to bottom out over bumps, damage to the suspension components and
symptoms similar to wheel alignment problems. Check the trim heights when diagnosing
suspension concerns and before checking the wheel alignment.
Perform the following before measuring the trim heights:
* Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle
Certification, Tire Placard, Anti-Theft, and Service Parts ID Label .
* Check the fuel level. Add additional weight if necessary to simulate a full tank. One U.S. gallon of
gasoline weighs approximately 6.5 lbs. One liter of gasoline weights approximately 0.70 kg.
* Make sure the passenger and rear compartments are empty, except tor the spare tire.
* Make sure the vehicle is on a flat and level surface, such as an alignment rack.
* For vehicles equipped with automatic level control, ensure the system is functioning properly.
* Check that all the vehicle doors are securely closed.
* Check that the vehicle hood and rear deck lids are securely closed.
* Check for installed after market accessories or modifications that could affect trim height
measurement:
- Larger of smaller than production wheels and tires
- Lifting or lowering kits
- Wheel opening flares or ground affects
Measuring the P and R Heights
Important: The left and right P and R height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the P and R dimensions:
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure vertically
from the ground to the bottom lip of the wheel opening through the centerline of the front wheel, P
height. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your
hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8.
Re-measure the P height as in step 4.
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9. The true P height is the average of the measurements taken in steps 4 and 8. Refer to Trim
Height Specifications (See: Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications) .
10. Repeat the above steps at the rear of the vehicle for the R heights. 11. If the P and R heights
are outside of specifications, measure the Z and D heights.
Measuring the Z Height
Measuring Z Height
Important:
*
In order to obtain the proper measurement, Z will equal inner minus the outer.
* The left and right Z height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the Z height:
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Repeat this
jouncing operation 2 more times for a total of 3 times. 5. Measure from the center of the lower ball
joint (A) to the alignment rack. 6. Measure from the center of the cradle (B) to the alignment rack. 7.
The difference between these 2 measurements is the Z height. 8. Push the front bumper of the
vehicle down about 38 mm (1.5 in). 9. Gently remove your hands and let the vehicle settle.
10. Repeat this operation 2 more times for a total of 3 times. 11. Re-measure the Z height as in
step 4. 12. The true Z height is the average of the measurements taken in steps 4 and 8. Refer to
Trim Height Specifications (See: Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications) .
If any of these measurements are out of specifications, inspect for the following conditions:
* Worn or damage suspension components
* Collision damage
Measuring the D Height
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Measuring D Height
Important:
* In order to obtain the proper measurement, D will equal inner minus the outer.
* The left and right D height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the D height:
1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure from the
center of the inner pivot bolt (A) to the alignment rack. 5. Measure from the center of the outer pivot
bolt (B) to the alignment rack. 6. The difference between these 2 measurements is the D height. 7.
Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 8. Gently remove your hands and let
the vehicle settle. 9. Repeat this operation 2 more times for a total of 3 times.
10. Re-measure the D height as in step 4. 11. The true D height is the average of the
measurements taken in steps 4 and 8. Refer to Trim Height Specifications (See:
Specifications/Mechanical
Specifications/Suspension/System Specifications/Trim Height Specifications) .
If any of these measurements are out of specifications, inspect for the following conditions:
* Worn or damage suspension components
* Collision damage
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Wheel Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering and Suspension/Steering/Specifications) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim
Height Inspection) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2433
Alignment: Service and Repair Front Camber Adjustment
Front Camber Adjustment
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the wheel
and tire assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
3. Remove the strut to knuckle nuts and bolts. Discard the nuts and bolts.
4. If the strut has not been previously modified, perform the following procedure:
1. Disconnect the strut from the knuckle.
Important:
* Maximum outboard adjustment-(increased negative camber) 2.0 mm of outboard elongation or to
within 11.0 mm from outboard edge of lower strut clevis bracket, whichever comes first
* Maximum inboard adjustment-(increased positive camber) 4.0 mm of inboard elongation
* If filing the strut, paint the exposed metal with primer.
2. If increasing negative camber, remove material from the outside of the lower strut hole. 3. If
decreasing negative camber, remove material from the inside of the lower strut hole.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2434
5. Loosely install new strut to knuckle nuts and bolts.
6. Adjust the camber to specifications by moving the top of the wheel in or out as necessary. Refer
to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
7. Tighten strut to knuckle nuts and bolts.
Tighten the nuts and bolts to 180 N.m (133 lb ft).
8. Install the wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2435
Alignment: Service and Repair Front Caster Adjustment
Front Caster Adjustment
The front caster is not adjustable. If the front caster angle is not within specifications, inspect for
suspension support misalignment or front suspension damage. Refer to Alignment Checking .
Replace any damaged suspension components as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2436
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
1. Position and lock the steering wheel with the vehicle with the wheels in the straight forward
position.
2. Loosen both inner tie rod jam nuts.
Important: The inner tie rod must rotate freely from the boot seal surface. Do not allow the boot to
rotate.
3. Loosen the inner tie rod seal to boot surface. 4. Use a wrench on the tie rod flats to increase or
decrease the toe angle specifications. Refer to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
5. Tighten the inner tie rod jam nuts.
Tighten the jam nuts to 60 N.m (44 lb ft).
6. Inspect the toe angle to ensure proper adjustment and adjust as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2437
Alignment: Service and Repair
Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Wheel Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering and Suspension/Steering/Specifications) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General
Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and
Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim
Height Inspection) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications) .
Front Camber Adjustment
Front Camber Adjustment
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the wheel
and tire assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2438
3. Remove the strut to knuckle nuts and bolts. Discard the nuts and bolts.
4. If the strut has not been previously modified, perform the following procedure:
1. Disconnect the strut from the knuckle.
Important:
* Maximum outboard adjustment-(increased negative camber) 2.0 mm of outboard elongation or to
within 11.0 mm from outboard edge of lower strut clevis bracket, whichever comes first
* Maximum inboard adjustment-(increased positive camber) 4.0 mm of inboard elongation
* If filing the strut, paint the exposed metal with primer.
2. If increasing negative camber, remove material from the outside of the lower strut hole. 3. If
decreasing negative camber, remove material from the inside of the lower strut hole.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2439
5. Loosely install new strut to knuckle nuts and bolts.
6. Adjust the camber to specifications by moving the top of the wheel in or out as necessary. Refer
to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
7. Tighten strut to knuckle nuts and bolts.
Tighten the nuts and bolts to 180 N.m (133 lb ft).
8. Install the wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Front Caster Adjustment
Front Caster Adjustment
The front caster is not adjustable. If the front caster angle is not within specifications, inspect for
suspension support misalignment or front suspension damage. Refer to Alignment Checking .
Replace any damaged suspension components as necessary.
Front Toe Adjustment
Front Toe Adjustment
1. Position and lock the steering wheel with the vehicle with the wheels in the straight forward
position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2440
2. Loosen both inner tie rod jam nuts.
Important: The inner tie rod must rotate freely from the boot seal surface. Do not allow the boot to
rotate.
3. Loosen the inner tie rod seal to boot surface. 4. Use a wrench on the tie rod flats to increase or
decrease the toe angle specifications. Refer to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
5. Tighten the inner tie rod jam nuts.
Tighten the jam nuts to 60 N.m (44 lb ft).
6. Inspect the toe angle to ensure proper adjustment and adjust as necessary.
Rear Camber Adjustment
Rear Camber Adjustment
1. Loosen the upper control arm-to-frame fastener enough to allow movement.
Important: The frame of the vehicle is slotted, turning the cam nut will move the camber in to the
designated location.
2. Rotate the upper control arm-to-frame fastener in the direction necessary to the correct the
camber measurement. 3. Snug the upper control arm-to-frame fastener, do not tighten at this time.
4. Reinspect the rear camber specifications and adjust as necessary.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Measurement > Page 2441
5. Hold the nut and tighten the upper control arm-to-frame bolt.
Tighten the bolt to 110 N.m (81 lb ft).
6. Repeat the procedure for the other rear wheel.
Rear Toe Adjustment
Rear Toe Adjustment
1. Loosen the suspension adjustment link-to-frame fastener enough to allow for movement.
Important: The frame of the vehicle is slotted, a cam nut is available for service if required.
2. Rotate the suspension adjustment link cam nut in the direction necessary to correct the toe
angle. 3. Snug the suspension adjustment link-to-frame fastener, do not tighten at this time. 4.
Reinspect the rear toe specifications and adjust as necessary.
Notice: Refer to Fastener Notice .
5. Hold the nut and tighten the link-to-frame fastener bolt.
Tighten the bolt to 110 N.m (81 lb ft).
6. Repeat the procedure for the other rear wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure.......................................................................................................................................
...............................................384-425 kPa (56-62 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information > Page 2448
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2451
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2452
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned
ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition
reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference
pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference
pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the
primary fuel tank module, eliminating the need for a return pipe from the engine. A returnless fuel
system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to
the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative
emissions.
An electric turbine style fuel pump attaches to the primary fuel tank module inside the fuel tank.
The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator,
and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint
that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of
the primary fuel tank module. The primary fuel tank module contains a reverse flow check valve.
The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the
fuel rail in order to prevent long cranking times.
The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel
pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet
pump and the secondary jet pump through a restrictive orifice located on the pump cover. The
primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates
a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through
the fuel transfer pipe, to the primary side of the fuel tank.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
*
Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Component
Tests and General Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 384-425 kPa (56-62 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2453
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 384-425 kPa
(56-62 psi).
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail.
3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan
tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF with
a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the primary fuel pump
module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the primary fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Powertrain Management/Computers and Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine
Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Replacement - Chassis
* Fuel Hose/Pipes Replacement - Engine Compartment
* Fuel Injector Replacement
* Primary Fuel Tank Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Inlet Duct Replacement
Removal Procedure
1. Loosen the clamps at both ends of the air cleaner intake duct. 2. Remove the positive crankcase
ventilation (PCV) fresh air pipe from the air cleaner intake duct. 3. Remove the air cleaner intake
duct from the mass air flow (MAF) sensor and throttle body.
Installation Procedure
1. Install the air cleaner intake duct to the MAF sensor and throttle body. 2. Install the PCV fresh air
pipe to the air cleaner intake duct.
Notice: Refer to Fastener Notice.
3. Tighten the clamps at both ends of the air cleaner intake duct.
Tighten the clamps to 4 N.m (35 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Release the clamps (2) on the side of the air cleaner assembly. 4. Remove the air cleaner
assembly lid (1) by tilting to release the lid from the lower housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 2464
5. Remove the air cleaner element (2) from the lower housing (1).
Installation Procedure
1. Install the air cleaner element (2) into the lower housing (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 2465
2. Install the air cleaner assembly lid (1) by first engaging the hinge then lower the cover into the
closed position. 3. Fasten the clamps (2) on the side of the air cleaner assembly.
4. Connect the MAF sensor electrical connector. 5. Install the air cleaner intake duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2471
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2472
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 2473
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
..................................................................1-2-3-4-5-6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
........................4,018 ohm per meter(1,225 ohmper ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 2480
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Refer to the list below
for items to be inspected.
1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2.
Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following
conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the
wire and the component connected to the wire should be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 2481
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the injector sight shield.
Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug
boot only. Do not pull on the spark plug wire or the wire could be damaged.
2. Remove the spark plug wires (1) from the left side spark plugs. 3. Remove the spark plug wires
from the retaining clips (2).
4. Remove the spark plug wires (1) from the right side spark plugs. 5. Remove the spark plug wires
from the retaining clips (2). 6. Remove the spark plug wires from the ignition coil/control module. 7.
Remove the spark plug wires from the engine. 8. If you are replacing the spark plug wires, transfer
any of the following components:
* Boot heat shields
* Spark plug wire conduit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 2482
* Spark plug wire retaining clips
Installation Procedure
1. Install the spark plug wires (1) to the ignition coil/control module. 2. Install the spark plug wires
(1) to the right side spark plugs. 3. Install the spark plug wires to the retaining clips (2).
4. Install the spark plug wires (1) to the left side spark plugs. 5. Install the spark plug wires to the
retaining clips (2). 6. Install the injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire
Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire
Warranty Extension > Page 2491
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire
Warranty Extension > Page 2492
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire
Warranty Extension > Page 2493
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign Spark Plug Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign Spark Plug Wire Warranty Extension > Page 2499
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign Spark Plug Wire Warranty Extension > Page 2500
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign Spark Plug Wire Warranty Extension > Page 2501
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 2502
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.........................................................1.52 mm (0.60 in)
Spark Plug Torque
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
Spark Plug Type
............................................................................................................................................
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 2503
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling-Colder plug
- Pre-ignition causing spark plug and/or engine damage-Hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 2504
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal
combustion by-products from fuels with additives.
* Carbon fouled-Dry, fluffy, black carbon or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 2505
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: Observe the following service precautions:
* Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from
a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads.
* Clean the spark plug recess area before removing the spark plug. Failure to do so can result in
engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the
cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.
* Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either
hotter or colder than those specified for the vehicle. Installing spark plugs of another type can
severely damage the engine.
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs (1) from the cylinder head.
Installation Procedure
Notice: It is important to check the gap of all new and reconditioned spark plugs before installation.
Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an
accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor
engine performance and may even damage the engine.
1. Gap the spark plugs to the specifications. Refer to Ignition System Specifications.
Notice: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if
necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can
cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque
specifications carefully. Over or under-tightening can also cause severe damage to engine or spark
plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 2506
Notice: Refer to Component Fastener Tightening Notice.
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
2. Install the spark plugs to the cylinder head.
Tighten the spark plugs to 15 N.m (11 lb ft).
3. Install the spark plug wires to the spark plugs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading
should be less than
................................................................................................................................................... 689
kPa (100 psi).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2510
Compression Check: Testing and Inspection
Engine Compression Test
A compression pressure test of the engine cylinders determines the condition of the rings, the
valves, and the head gasket.
Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse
block. Refer to Electrical Center Identification Views .
1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the
cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open
position. 6. Measure the engine compression, using the following procedure:
1. Firmly install the compression gauge to the spark plug hole. 2. Have an assistant crank the
engine through at least 4 compression strokes in the testing cylinder. 3. Record the readings on the
gauge at each stroke. 4. Disconnect the gauge. 5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
* The lowest reading should not be less than 70 percent of the highest reading.
* No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements:
* When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
* When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, the piston rings may be the cause.
* If the compression improves considerably with the addition of three squirts of oil, the piston rings
may be the cause.
* When the compression is low on the first stroke and does not build up in the following strokes, the
valves may be the cause.
* The addition of oil does not affect the compression, the valves may be the cause.
* When the compression is low on two adjacent cylinders, or coolant is present in the crankcase,
the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain
Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
^ Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain
dampener (1).
^ Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the
crankshaft gear.
^ Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain
dampener (3).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 2518
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine
- Drive Belt Misalignment Diagnostics > Page 2519
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
2520
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page
2521
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend
backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt
style belt used to drive certain accessory drive components. The drive belts are made of different
types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two
or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for
being bent should include inspecting for a dent or other damage to the pulleys that would prevent
the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a
pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the
drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper
belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal
noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt
tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be
routed properly and may be turning an accessory drive component in the wrong direction. 16.
Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley
grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive
component for the proper installation procedure for that pulley. 17. This test is to verify that the
pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2524
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2525
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2526
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2527
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2528
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt
Chirping, Squeal, and Whine Diagnosis > Page 2529
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2530
Drive Belt: Service and Repair
Drive Belt Replacement
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 3.
Remove the drive belt from the right idler pulley (2). 4. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 5. Remove J 39914 from the drive belt tensioner (8). 6. Provided the
vehicle will not be raised or lifted to perform additional work. Utilizing a floor jack and a wood block,
support the front of the engine
using the following procedure.
1. Place the wood block between the lift point of the floor jack and the bottom of the engine oil pan.
2. Raise the jack until the wood block comes into contact with the engine oil pan and is capable of
supporting the weight of the engine.
7. If the vehicle is to be raised or lifted in order to perform additional work. Support the engine using
the engine support fixture. Refer to Engine
Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and
Replacement/Engine Support Fixture) .
8. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine,
Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Engine Mount/Service and Repair) .
9. Remove the drive belt from the remaining pulleys.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2531
Installation Procedure
1. Install the drive belt to all the pulleys except the right idler pulley. 2. Install the right engine
mount. Refer to Engine Mount Replacement - Right Side (See: Engine, Cooling and
Exhaust/Engine/Drive Belts, Mounts,
Brackets and Accessories/Engine Mount/Service and Repair) .
3. Depending on which method was used to support the engine. Remove the floor jack from under
the engine oil pan or remove the engine support
fixture.
4. Using J 39914 rotate the drive belt tensioner away from the drive belt. 5. Install the drive belt to
the right idler pulley (2). 6. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 7. Remove J 39914 from the drive belt tensioner (8). 8. Inspect the drive
belt to insure the belt is properly centered on all pulleys (1-8). 9. Install the air cleaner assembly.
Refer to Air Cleaner Assembly Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose >
Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Inlet Duct Replacement
Removal Procedure
1. Loosen the clamps at both ends of the air cleaner intake duct. 2. Remove the positive crankcase
ventilation (PCV) fresh air pipe from the air cleaner intake duct. 3. Remove the air cleaner intake
duct from the mass air flow (MAF) sensor and throttle body.
Installation Procedure
1. Install the air cleaner intake duct to the MAF sensor and throttle body. 2. Install the PCV fresh air
pipe to the air cleaner intake duct.
Notice: Refer to Fastener Notice.
3. Tighten the clamps at both ends of the air cleaner intake duct.
Tighten the clamps to 4 N.m (35 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Release the clamps (2) on the side of the air cleaner assembly. 4. Remove the air cleaner
assembly lid (1) by tilting to release the lid from the lower housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair > Page 2540
5. Remove the air cleaner element (2) from the lower housing (1).
Installation Procedure
1. Install the air cleaner element (2) into the lower housing (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information
> Service and Repair > Page 2541
2. Install the air cleaner assembly lid (1) by first engaging the hinge then lower the cover into the
closed position. 3. Fasten the clamps (2) on the side of the air cleaner assembly.
4. Connect the MAF sensor electrical connector. 5. Install the air cleaner intake duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement
Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Housing Replacement
Passenger Compartment Air Filter Housing Replacement
Removal Procedure
1. Remove the push pins from the rear of the RH air inlet panel.
2. Open the hood. 3. Remove the push pins from the top and forward edge of the RH air inlet
panel. 4. Remove the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2546
5. Remove the RH air inlet panel. 6. Remove the LH air inlet panel.
7. Remove the filter housing nuts from the vehicle. 8. Remove the filter housing from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2547
1. Inspect the foam seal. If the seal is damaged, replace the seal using Kent Industries adhesive
back foam tape P/N 46485 (or equivalent). 2. Install the filter housing to the vehicle.
Notice: Refer to Fastener Notice.
Important: New seal nuts must be used when installing passenger compartment air filter housing to
prevent leaks.
3. Install the new seal nuts to the filter housing.
Tighten the nuts to 9 N.m (80 lb in).
4. Install the LH air inlet panel. 5. Install the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2548
6. Install the push pins and screw to the top and forward edge of the RH air inlet panel. 7. Close the
hood.
8. Install the push pins to the rear of the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2549
Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Replacement
Passenger Compartment Air Filter Replacement
Removal Procedure
1. Remove the push pins from the rear of the RH air inlet panel.
2. Open the hood. 3. Remove the push pins from the top and forward edge of the RH air inlet
panel. 4. Remove the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2550
5. Remove the RH air inlet panel.
6. Remove the filter from the filter housing by depressing the release tab at the inboard edge of the
filter housing. 7. Remove the filter from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2551
1. Install the filter to the vehicle.
2. Install the RH air inlet panel. 3. Install the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Passenger Compartment Air Filter Housing Replacement > Page 2552
4. Install the push pins to the top and forward edge of the RH air inlet panel. 5. Close the hood.
6. Install the push pins to the rear of the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and
Repair
Evaporative Canister Filter: Service and Repair
Evaporative Emission Canister Filter Replacement
Removal Procedure
Important: The evaporative emission (EVAP) canister filter cover must also be replaced when the
EVAP filter is replaced to ensure proper operation of the EVAP canister.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the EVAP canister from the
vehicle.
3. Carefully release the canister filter cover rear retaining tabs. 4. Carefully release the canister
filter cover forward retaining tabs and remove the cover from the EVAP canister. 5. Discard the
EVAP canister filter cover.
6. Remove the filter from the canister and discard the filter. 7. Clean the inside of the EVAP
canister filter housing with a clean shop towel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and
Repair > Page 2556
1. Install a NEW filter to the canister filter housing.
Important: Ensure that the seal is properly seated in the NEW EVAP filter cover.
2. Install a NEW EVAP filter cover to the EVAP canister. 3. Install the EVAP canister to the vehicle.
4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2562
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2563
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information >
Service and Repair > Procedures > Page 2564
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Engine - Noise/Damage Oil Filter Application Importance
Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 2569
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position the oil drain
pan under the engine oil drain plug.
3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, replace if
necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or
replace oil pan if necessary.
6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair
or replace if necessary.
Installation Procedure
1. Lightly oil the replacement oil filter gasket with clean oil .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 2570
Notice: Refer to Component Fastener Tightening Notice .
2. Install the new oil filter. Refer to Maintenance Items .
Tighten the filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug.
Tighten the plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service
Bulletins > Page 2571
6. Remove the oil fill cap from the rocker arm cover. 7. Fill the engine with new engine oil. Refer to
Approximate Fluid Capacities , Fluid and Lubricant Recommendations and Maintenance Schedule
(North American Emissions) .
8. Install the oil fill cap to the rocker arm cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement
Coolant Line/Hose: Service and Repair Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Release and slide the heater core inlet hose clamp away from the heater inlet pipe connection.
4. Disconnect the heater core inlet hose from the heater inlet pipe.
5. Remove the heater inlet pipe nut (2). 6. Remove the heater inlet pipe (1). 7. Remove the seal (3)
from the heater inlet pipe (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2577
1. Install a new seal (3) to the heater inlet pipe (1). 2. Apply engine coolant to the heater inlet pipe
seal (3).
3. Install the heater outlet pipe (1).
Notice: Refer to Fastener Notice .
4. Install the heater inlet pipe nut (2).
Tighten the nut to 25 N.m (18 lb ft).
5. Connect the heater core inlet hose to the heater inlet pipe. 6. Position the heater core inlet hose
clamp over the heater inlet pipe connection. 7. Fill the cooling system. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
8. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2578
Coolant Line/Hose: Service and Repair Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Remove the heater outlet hose clamps (1). 4. Remove the heater outlet hose (2).
Installation Procedure
1. Apply engine coolant to the heater outlet hose in order to ease installation.
2. Install the heater outlet hose (2). 3. Install the heater outlet hose clamps (1). 4. Fill the cooling
system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and
Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2579
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2580
Coolant Line/Hose: Service and Repair Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Remove the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
4. Remove the manifold absolute pressure (MAP) sensor bolt (3) and bracket (2). 5. Rotate the
MAP sensor out of the way of the heater outlet pipe. 6. Disconnect the evaporative emissions
(EVAP) pipe from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting
Service
.
7. Disconnect the electrical connector from the EVAP canister purge solenoid. 8. Disconnect the
exhaust gas recirculation (EGR) valve electrical connector.
9. Release and slide the heater outlet hose clamp (1) away from the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2581
10. Disconnect the heater outlet hose (2) from the heater outlet pipe.
11. Release and slide the heater core outlet hose clamp away from the heater outlet pipe
connection. 12. Disconnect the heater core outlet hose from the heater outlet pipe.
13. Remove the wire harness retaining clip (1) from the heater pipe bracket. 14. Remove the fuel
pipe retaining clip (2) from the heater pipe bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2582
15. Remove the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
16. Remove the two nuts (3) and bolt (4) securing the heater outlet pipe to the throttle body. 17.
Remove the heater outlet pipe (2) from the engine.
Installation Procedure
1. Install the heater outlet pipe (2) to the engine.
Notice: Refer to Fastener Notice .
2. Install the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
Tighten the nut to 25 N.m (18 lb ft).
3. Install the heater outlet pipe to the throttle body nuts (3) and bolt (4).
Tighten the nuts and bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2583
4. Install the fuel pipe retaining clip (2) to the heater pipe bracket. 5. Install the wire harness
retaining clip (1) to the heater pipe bracket.
6. Connect the heater core outlet hose to the heater outlet pipe. 7. Position the heater core outlet
hose clamp over the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2584
8. Connect the heater outlet hose (2) to the heater outlet pipe. 9. Position the heater outlet hose
clamp (1) over the heater outlet pipe connection.
10. Connect the electrical connector to the EGR valve. 11. Connect the electrical connector to the
EVAP canister purge solenoid. 12. Connect the EVAP pipe to the EVAP canister purge solenoid.
Refer to Plastic Collar Quick Connect Fitting Service .
13. Reposition the MAP sensor. 14. Install the MAP sensor bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
15. Install the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement . 16. Fill the
cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling
and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
17. Install the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2585
Coolant Line/Hose: Service and Repair Thermal Bypass Fitting Replacement
Thermal Bypass Fitting Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Release and slide the thermal bypass pipe hose clamp (2) away from the thermal bypass fitting.
4. Remove the thermal bypass hose (1) from the thermal bypass fitting.
5. Release and slide the heater outlet hose clamp (1) away from the thermal bypass fitting. 6.
Remove the heater outlet hose (2) from the thermal bypass fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2586
7. Remove the thermal bypass fitting bolt (2). 8. Remove the thermal bypass fitting (1). 9. Remove
the seal from the thermal bypass fitting.
Installation Procedure
1. Install a new seal to the thermal bypass fitting. 2. Apply engine coolant to the thermal bypass
fitting seal to ease installation.
3. Install the thermal bypass fitting (1).
Notice: Refer to Fastener Notice .
4. Install the thermal bypass fitting bolt (2).
Tighten the bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2587
5. Install the heater outlet hose (2) to the thermal bypass fitting. 6. Position the heater outlet hose
clamp (1) over the thermal bypass fitting.
7. Install the thermal bypass hose (1) to the thermal bypass fitting. 8. Position the thermal bypass
pipe hose clamp (2) over the thermal bypass fitting. 9. Fill the cooling system. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2588
Coolant Line/Hose: Service and Repair
Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Release and slide the heater core inlet hose clamp away from the heater inlet pipe connection.
4. Disconnect the heater core inlet hose from the heater inlet pipe.
5. Remove the heater inlet pipe nut (2). 6. Remove the heater inlet pipe (1). 7. Remove the seal (3)
from the heater inlet pipe (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2589
Installation Procedure
1. Install a new seal (3) to the heater inlet pipe (1). 2. Apply engine coolant to the heater inlet pipe
seal (3).
3. Install the heater outlet pipe (1).
Notice: Refer to Fastener Notice .
4. Install the heater inlet pipe nut (2).
Tighten the nut to 25 N.m (18 lb ft).
5. Connect the heater core inlet hose to the heater inlet pipe. 6. Position the heater core inlet hose
clamp over the heater inlet pipe connection. 7. Fill the cooling system. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
8. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2590
Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Remove the heater outlet hose clamps (1). 4. Remove the heater outlet hose (2).
Installation Procedure
1. Apply engine coolant to the heater outlet hose in order to ease installation.
2. Install the heater outlet hose (2). 3. Install the heater outlet hose clamps (1). 4. Fill the cooling
system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and
Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2591
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Remove the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
4. Remove the manifold absolute pressure (MAP) sensor bolt (3) and bracket (2). 5. Rotate the
MAP sensor out of the way of the heater outlet pipe. 6. Disconnect the evaporative emissions
(EVAP) pipe from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting
Service
.
7. Disconnect the electrical connector from the EVAP canister purge solenoid. 8. Disconnect the
exhaust gas recirculation (EGR) valve electrical connector.
9. Release and slide the heater outlet hose clamp (1) away from the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2592
10. Disconnect the heater outlet hose (2) from the heater outlet pipe.
11. Release and slide the heater core outlet hose clamp away from the heater outlet pipe
connection. 12. Disconnect the heater core outlet hose from the heater outlet pipe.
13. Remove the wire harness retaining clip (1) from the heater pipe bracket. 14. Remove the fuel
pipe retaining clip (2) from the heater pipe bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2593
15. Remove the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
16. Remove the two nuts (3) and bolt (4) securing the heater outlet pipe to the throttle body. 17.
Remove the heater outlet pipe (2) from the engine.
Installation Procedure
1. Install the heater outlet pipe (2) to the engine.
Notice: Refer to Fastener Notice .
2. Install the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
Tighten the nut to 25 N.m (18 lb ft).
3. Install the heater outlet pipe to the throttle body nuts (3) and bolt (4).
Tighten the nuts and bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2594
4. Install the fuel pipe retaining clip (2) to the heater pipe bracket. 5. Install the wire harness
retaining clip (1) to the heater pipe bracket.
6. Connect the heater core outlet hose to the heater outlet pipe. 7. Position the heater core outlet
hose clamp over the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2595
8. Connect the heater outlet hose (2) to the heater outlet pipe. 9. Position the heater outlet hose
clamp (1) over the heater outlet pipe connection.
10. Connect the electrical connector to the EGR valve. 11. Connect the electrical connector to the
EVAP canister purge solenoid. 12. Connect the EVAP pipe to the EVAP canister purge solenoid.
Refer to Plastic Collar Quick Connect Fitting Service .
13. Reposition the MAP sensor. 14. Install the MAP sensor bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
15. Install the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement . 16. Fill the
cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling
and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
17. Install the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Fitting Replacement
Thermal Bypass Fitting Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2596
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
3. Release and slide the thermal bypass pipe hose clamp (2) away from the thermal bypass fitting.
4. Remove the thermal bypass hose (1) from the thermal bypass fitting.
5. Release and slide the heater outlet hose clamp (1) away from the thermal bypass fitting. 6.
Remove the heater outlet hose (2) from the thermal bypass fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2597
7. Remove the thermal bypass fitting bolt (2). 8. Remove the thermal bypass fitting (1). 9. Remove
the seal from the thermal bypass fitting.
Installation Procedure
1. Install a new seal to the thermal bypass fitting. 2. Apply engine coolant to the thermal bypass
fitting seal to ease installation.
3. Install the thermal bypass fitting (1).
Notice: Refer to Fastener Notice .
4. Install the thermal bypass fitting bolt (2).
Tighten the bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2598
5. Install the heater outlet hose (2) to the thermal bypass fitting. 6. Position the heater outlet hose
clamp (1) over the thermal bypass fitting.
7. Install the thermal bypass hose (1) to the thermal bypass fitting. 8. Position the thermal bypass
pipe hose clamp (2) over the thermal bypass fitting. 9. Fill the cooling system. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Hose Replacement
Thermal Bypass Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2599
3. Release and slide the thermal bypass pipe hose clamps (2) away from the hose connections. 4.
Remove thermal bypass hose (1).
Installation Procedure
1. Apply engine coolant to the bypass hose in order to ease installation.
2. Install the thermal bypass pipe hose (1). 3. Position the thermal bypass pipe hose clamps (2)
over the hose end connections. 4. Fill the cooling system. Refer to Cooling System Draining and
Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Pipe Replacement
Thermal Bypass Pipe Replacement
Tools Required
J 21882 Oil Suction Pipe Installer
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2600
System/Service and Repair)Cooling System Draining and Filling (LY7 Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) .
2. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement (See: Engine,
Cooling and Exhaust/Engine/Intake
Manifold/Service and Repair) .
3. Remove the thermal bypass hose. Refer to Thermal Bypass Hose Replacement (See: ) .
4. Remove the thermal bypass pipe bolt. 5. Remove the thermal bypass pipe .
Installation Procedure
1. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the end of the
thermal bypass pipe where the pipe is pressed into the
intake manifold.
2. Install the thermal bypass pipe using J 21882 .
Notice: Refer to Fastener Notice .
3. Install the thermal bypass pipe bolt.
Tighten the bolt to 10 N.m (89 lb in).
4. Install the thermal bypass hose. Refer to Thermal Bypass Hose Replacement (See: ) . 5. Install
the upper intake manifold. Refer to Upper Intake Manifold Replacement (See: Engine, Cooling and
Exhaust/Engine/Intake
Manifold/Service and Repair) .
6. Fill the engine with coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
> Heater Inlet Pipe Replacement > Page 2601
and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ)
Heater Hose: Service and Repair Heater Inlet Hose Replacement (LNJ)
Heater Inlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater inlet hose clamp from the heater core. 3. Remove the heater inlet hose (2)
from the heater core.
4. Remove the heater inlet hose clamp from the engine. 5. Remove the heater inlet hose (2) from
the engine. 6. Remove the heater inlet hose (2) from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ) > Page 2606
Installation Procedure
1. Install the heater inlet hose (2) to the vehicle. 2. Install the heater inlet hose (2) to the engine. 3.
Install the heater inlet hose clamp to the engine.
4. Install the heater inlet hose (2) to the heater core. 5. Install the heater inlet hose clamp to the
heater core. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ) > Page 2607
Heater Hose: Service and Repair Heater Outlet Hose Replacement (LNJ)
Heater Outlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater outlet hose clamp from the heater core. 3. Remove the heater outlet hose (1)
from the heater core.
4. Remove the heater outlet hose clamp from the engine. 5. Remove the heater outlet hose (1)
from the engine. 6. Position the loose end of the heater outlet hose (1) outboard to ease in the
removal of the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ) > Page 2608
7. Remove the surge tank inlet hose clamp from the surge tank. 8. Disconnect the surge tank inlet
hose from the surge tank.
9. Remove the surge tank bolts from the surge tank.
10. Lift the surge tank to gain access to the heater outlet hose. 11. Remove the heater outlet hose
clamp from the surge tank. 12. Remove the heater outlet hose from the surge tank. 13. Remove
the surge tank from the vehicle. 14. Remove the heater outlet hose clamp from the hose. This will
aid in routing the heater outlet hose from the vehicle. 15. Remove the heater outlet hose from the
vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ) > Page 2609
1. Install the heater outlet hose to the vehicle. Route the hose into position for attachment to the
surge tank. 2. Install the heater outlet hose clamp to the hose. 3. Install the heater outlet hose to
the surge tank. 4. Install the surge tank to the vehicle.
Notice: Refer to Fastener Notice.
5. Install the surge tank bolts to the surge tank.
Tighten the bolts to 8 N.m (71 lb in).
6. Connect the surge tank inlet hose to the surge tank. 7. Install the surge tank inlet hose clamp to
the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair >
Heater Inlet Hose Replacement (LNJ) > Page 2610
8. Install the heater outlet hose (1) to the engine. 9. Install the heater outlet hose clamp to the
engine.
10. Install the heater outlet hose (1) to the heater core. 11. Install the heater outlet hose clamp to
the heater core. 12. Fill the engine coolant. Refer to Cooling System Draining and Filling (LNJ
Static Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ)
Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement (LNJ)
Compressor Hose Assembly Replacement (LNJ)
Special Tools
J 39400-A Halogen Leak Detector
Removal Procedures
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the left
headlamp.
3. Remove the compressor hose retainer nut from the battery box. 4. Remove the evaporator outlet
hose nut from the evaporator outlet hose. 5. Remove the evaporator outlet hose from the
compressor hose. 6. Install a protective cap to the evaporator outlet hose to prevent contamination
and desiccant saturation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2615
7. Remove the compressor hose nut from the condenser. 8. Remove the compressor hose from
the condenser. 9. Install a protective cap to the condenser to prevent contamination and desiccant
saturation.
10. Raise and support the vehicle. Refer to Vehicle Lifting.
11. Disconnect the electrical connector from the pressure transducer. 12. Remove the compressor
hose nut at the compressor. 13. Remove the compressor hose from the compressor. 14. Install a
protective cap to the compressor to prevent contamination and desiccant saturation. 15. Remove
the compressor hose from the vehicle. 16. Remove and discard the sealing washers from the
compressor hose.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2616
1. Remove protective cap from compressor end of the compressor hose and the compressor. 2.
Install new seal washers to the compressor hose. 3. Install the compressor hose to the
compressor.
Notice: Refer to Fastener Notice.
4. Install the compressor hose nut to the compressor.
Tighten the nut to 20 N.m (15 lb ft).
5. Connect the electrical connector to the pressure transducer.
6. Lower the vehicle. 7. Position the compressor hose in the vehicle. 8. Install a new sealing
washer to the evaporator outlet hose. 9. Install the evaporator outlet hose to the compressor hose.
10. Install the evaporator outlet hose nut to the evaporator outlet hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2617
Tighten the nut to 20 N.m (15 lb ft).
11. Install a new sealing washer to the compressor hose at the condenser. 12. Install the
compressor hose to the condenser. 13. Install the compressor hose nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
14. Install the compressor hose retainer nut to the battery box.
Tighten the nut to 9 N.m (80 lb in).
15. Install the left headlamp. 16. Recharge the A/C system. Refer to Refrigerant Recovery and
Recharging. 17. Test the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2618
Hose/Line HVAC: Service and Repair Evaporator Outlet Hose Replacement
Evaporator Outlet Hose Replacement
Tools Required
J 39400-A Halogen Leak Detector
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the
evaporator outlet hose nut from the evaporator outlet hose. 3. Remove the evaporator outlet hose
from the compressor hose.
4. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion
valve (TXV). 5. Remove the evaporator outlet hose and liquid line from the TXV. 6. Remove
evaporator outlet hose from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2619
7. Remove and discard the sealing washers from the evaporator outlet hose and the compressor
hose. 8. Install protective caps to the TXV, the liquid line, and the compressor hose to prevent
contamination and desiccant saturation.
Installation Procedure
1. Remove the protective caps from the TXV, the liquid line, and the compressor hose. 2. Install
new sealing washers to the evaporator outlet hose, liquid line, and the compressor hose. 3. Install
the evaporator outlet hose and the liquid line to the TXV.
Notice: Refer to Fastener Notice.
4. Install the evaporator outlet hose and the liquid line nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
5. Install the evaporator outlet hose to the compressor hose. 6. Install the evaporator outlet hose
nut to the evaporator outlet hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2620
Tighten the nut to 20 N.m (15 lb ft).
7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Test the affected
A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2621
Hose/Line HVAC: Service and Repair Liquid Line Replacement
Liquid Line Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the left
headlamp. 3. Remove the surge tank. 4. Remove the washer bottle. 5. Remove the battery. 6.
Remove the battery box bolts from the battery box. 7. Disconnect the negative battery cable nut
from the wheelhouse.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2622
8. Remove the nut retaining the liquid line to the strut tower. 9. Disconnect the harness and vent
hose retainers from the liquid line.
10. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion
valve (TXV). 11. Remove the evaporator outlet hose and liquid line from the TXV.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2623
12. Remove the liquid line nut from the condenser. 13. Remove the liquid line from the condenser.
14. Remove the bolt retaining the liquid line to the body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2624
15. Position the battery box inboard to allow for routing of the liquid line. 16. Route the liquid line
above the battery box and the ground lug. 17. Lift the rear portion of the liquid line upward and
remove the liquid line from the vehicle. 18. Remove and discard the sealing washer from the liquid
line. 19. Install protective caps to the condenser, the evaporator outlet hose, and the TXV to
prevent contamination and desiccant saturation.
Installation Procedure
1. Route the liquid line below the battery box and the ground lug.
Notice: Refer to Fastener Notice.
2. Connect the negative battery cable nut to the wheelhouse.
Tighten the nut to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2625
3. Remove the protective caps from the condenser, the evaporator outlet hose, and the TXV. 4.
Install the new sealing washer to the liquid line. 5. Route the condenser end of the liquid line into
position. 6. Install the liquid line to the condenser.
Important: Use a large pair of pliers to hold the fitting while tightening the nut. Be careful not to twist
the line.
7. Install the liquid line nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
8. Install the bolt to retain the liquid line to the body.
Tighten the nut to 9 N.m (80 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2626
9. Remove the protective cap from the TXV, the liquid line, and the evaporator outlet hose.
10. Install new seal washers to the liquid line and the evaporator outlet hose. 11. Install the liquid
line and the evaporator outlet hose to the TXV. 12. Install the liquid line and evaporator outlet hose
retainer plate nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
13. Install the four battery box bolts to the inside of the battery box.
Tighten the nut to 15 N.m (11 lb ft).
14. Install the battery box bolt to the outside of the battery box.
Tighten the nut to 10 N.m (86 lb in).
15. Install the battery.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor Hose Assembly Replacement (LNJ) > Page 2627
16. Install the liquid line to the strut tower. 17. Install the liquid line nut to the strut tower.
Tighten the nut to 9 N.m (80 lb in).
18. Connect the harness and vent hose retainers to the liquid line. 19. Install the surge tank. 20.
Install the washer bottle. 21. Install the left headlamp. 22. Recharge the A/C system. Refer to
Refrigerant Recovery and Recharging. 23. Test the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service
Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Notice
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement
Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Outlet Hose
Replacement
Power Steering Fluid Reservoir Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 2.
Remove as much power steering fluid from the remote power steering fluid reservoir as possible. 3.
Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement . 4. Place
drain pans under the vehicle as needed.
5. Compress the power steering reservoir outlet hose clamp (1) and disconnect the power steering
reservoir outlet hose (2) from the remote power
steering fluid reservoir.
6. Compress the power steering reservoir outlet hose clamp (1) and disconnect the power steering
reservoir outlet hose (2) from the power steering
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2633
pump.
7. Remove the power steering reservoir outlet hose.
Installation Procedure
1. Position the power steering reservoir outlet hose to the vehicle.
2. Compress the power steering reservoir outlet hose clamp (1) and connect the power steering
reservoir outlet hose (2) to the power steering pump.
3. Compress the power steering reservoir outlet hose clamp (1) and connect the power steering
reservoir outlet hose (2) to the remote power steering
fluid reservoir.
4. Clean any excess power steering fluid from the vehicle and remove the drain pans. 5. Install the
right side engine splash shield. Refer to Engine Splash Shield Replacement . 6. Install the fuel
injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 7. Fill and bleed the power
steering system. Refer to Power Steering System Bleeding (See: Steering and
Suspension/Steering/Power Steering/Power
Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2634
Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement
Power Steering Cooler Pipe/Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 2.
Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . 3. Remove as
much power steering fluid from the remote power steering fluid reservoir as possible. 4. Remove
the front tire/wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels
and Tires/Service and Repair) . 5. Remove the left side engine splash shield. Refer to Engine
Splash Shield Replacement . 6. Place drain pans under the vehicle as needed.
7. Compress the power steering cooler pipe clamp (1) and disconnect the power steering cooler
pipe (2) from the remote power steering fluid
reservoir.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2635
8. Disconnect the power steering cooler pipe fitting (1) from the power steering gear. 9. Unclip all
power steering cooler pipe routing brackets.
10. Remove the power steering cooler pipe from the vehicle.
Installation Procedure
1. Position the power steering cooler pipe to the vehicle. 2. Reconnect all power steering cooler
pipe routing brackets to the vehicle.
Notice: Refer to Fastener Notice .
3. Connect the power steering cooler pipe fitting (1) to the power steering gear.
Tighten to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2636
4. Compress the power steering cooler pipe clamp (1) and connect the power steering cooler pipe
(2) to the remote power steering fluid reservoir. 5. Clean any excess power steering fluid from the
vehicle and remove the drain pans. 6. Install the left side engine splash shield. Refer to Engine
Splash Shield Replacement . 7. Install the front tire/wheel assemblies. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair) . 8. Install the air cleaner
outlet duct. Refer to Air Cleaner Outlet Duct Replacement . 9. Install the fuel injector sight shield.
Refer to Fuel Injector Sight Shield Replacement .
10. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See:
Steering and Suspension/Steering/Power Steering/Power
Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2637
Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement
Power Steering Gear Inlet Pipe/Hose Replacement
Removal Procedure
1. Remove the front tire/wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) . 2. Place drain pans under the vehicle as needed. 3.
Remove as much fluid from the remote power steering fluid reservoir as possible.
4. Disconnect the power steering gear inlet hose fitting (1) from the power steering pump.
5. Disconnect the power steering gear inlet hose fitting (1) from the steering gear. 6. Remove the
power steering gear inlet hose from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2638
Installation Procedure
1. Position the steering gear inlet hose to the vehicle.
Notice: Refer to Fastener Notice .
Important: Hand tighten the power steering gear inlet hose fittings before finalizing the torques.
2. Connect the power steering gear inlet hose fitting (1) to the steering gear.
Tighten the fitting to 25 N.m (18 lb ft).
3. Connect the power steering gear inlet hose fitting (1) to the power steering pump.
Tighten the fitting to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 2639
4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the front tire/wheel
assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) . 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding
(See: Steering and Suspension/Steering/Power Steering/Power
Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (LNJ 3.4L Chevrolet)
Removal Procedure
1. Drain the coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and
Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair )Cooling System Draining and Filling (LY7 Static Fill)
(See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining
and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and
Repair) .
2. Remove the upper fascia retainers from the radiator support. 3. Remove the upper radiator
bracket bolt from the radiator support. 4. Remove the upper radiator bracket from the radiator. 5.
Remove the radiator inlet hose clamp from the radiator.
6. Remove the radiator inlet hose from the radiator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 2644
7. Remove the radiator inlet hose clamp from the engine. 8. Remove the radiator inlet hose from
the engine.
Installation Procedure
1. Install the radiator inlet hose to the engine. 2. Install the radiator inlet hose clamp to the engine.
3. Install the radiator inlet hose to the radiator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 2645
4. Install the radiator inlet hose clamp to the radiator. 5. Install the upper radiator bracket to the
radiator.
Notice: Refer to Fastener Notice .
6. Install the upper radiator bracket bolt to the radiator support.
Tighten the bolt to 20 N.m (15 lb ft).
7. Install the upper fascia retainers to the radiator support. 8. Fill the cooling system. Refer to
Cooling System Draining and Filling (LNJ Static Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 2646
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (LNJ) (3.4L)
Removal Procedure
1. Drain the coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and
Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair )Cooling System Draining and Filling (LY7 Static Fill)
(See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining
and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and
Repair) .
2. Remove the radiator outlet hose clamp from the engine. 3. Remove the radiator outlet hose from
the engine.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 5. Remove the radiator
outlet hose clamp from the radiator. 6. Remove the radiator outlet hose from the radiator.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair >
Radiator Inlet Hose Replacement > Page 2647
1. Install the radiator outlet hose to the radiator. 2. Install the radiator outlet hose clamp to the
radiator. 3. Lower the vehicle.
4. Install the radiator outlet hose to the engine. 5. Install the radiator outlet hose clamp to the
engine. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill)
(See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Engine,
Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Engine, Cooling and Exhaust/Cooling
System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM
Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Bulletin No.: 05-06-02-002B
Date: January 18, 2008
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Number 05-06-02-002A (Section 06 - Engine/Propulsion System).
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Cooling System ...................................................................................................................................
................................................ 10.5 quarts (9.9 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 2658
Coolant: Fluid Type Specifications
ENGINE COOLANT
The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is
designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs
first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will:
^ Give freezing protection down to -34°F (-37°C).
^ Give boiling protection up to 265°F (129°C).
^ Protect against rust and corrosion.
^ Help keep the proper engine temperature.
^ Let the warning lights and gages work as they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE
Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't
damage aluminum parts. If you use this coolant mixture, you don't need to add anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - Water Or Coolant Contamination Information
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins
> A/T - Water Or Coolant Contamination Information > Page 2663
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
AF33-5 - Automatic Transaxle
Complete Overhaul ..............................................................................................................................
....................................................... 7.8L (8.2 Quarts) Remove Drain Plug and Fill .............................
...................................................................................................................................... 4.06L (4.29
Quarts)
6T70/6T75 - Automatic Transmission
Valve Body Cover Removal
..........................................................................................................................................................
5.0-7.0L (5.3-7.4 Quarts) Overhaul .....................................................................................................
.................................................................................... 7.0-9.0L (7.4-9.5 Quarts) Fluid Change- Drain
Plug
..............................................................................................................................................................
4.0-6.0L (4.2-6.3 Quarts)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 2666
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID
5-Speed Automatic Transmission Use only T-IV Automatic Transmission Fluid (GM Part No. U.S.
88900925, in Canada 22689186).
NOTICE: Use of the incorrect automatic transaxle fluid may damage your vehicle, and the
damages may not be covered by your warranty.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection >
AF33-5 Transmission Fluid Checking Procedure
Fluid - A/T: Testing and Inspection AF33-5 Transmission Fluid Checking Procedure
Transmission Fluid Check
Description
Inspection of the transaxle fluid level, correct type of fluid, and the condition of the fluid for accurate
operation of the transaxle.
Procedure
Important: Routine inspection of the transaxle fluid is not required. Transaxle fluid inspection is only
required if there is a symptom indicating a concern with the fluid.
1. Park the vehicle on a flat level surface. 2. Operate the vehicle in order for the transmission fluid
temperature to reach the normal operating range.
Transaxle normal temperature: 60-70 degrees C (140-158 degrees F)
3. With the engine at idle, manual shift through all transaxle ranges and return to the PARK
position. Leave the engine idling. 4. Clean any dirt or debris away from the area of the transaxle
fluid level indicator. 5. Remove the transaxle fluid level indicator bolt (1) from the transaxle. 6.
Remove the transaxle fluid level indicator (2). 7. Wipe away any transaxle fluid from the indicator.
8. Insert the indicator into the transaxle until fully seated.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection >
AF33-5 Transmission Fluid Checking Procedure > Page 2669
Important: Inspecting transaxle fluid level when not at normal temperature can give an incorrect
measurement. The transaxle fluid expands when warm.
9. Remove the indicator and inspect the level and the condition of the oil on the indicator:
* Transmission fluid level at normal operating temperature (1)
* Transmission fluid level if cold (2)
10. If the fluid level is incorrect inspect for the following conditions:
* Fluid below level, inspect for a leak. Refer to Fluid Leak Diagnosis (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic
Procedures/AF33-5 - Automatic Transaxle/Fluid Leak Diagnosis ) or Automatic Transmission Fluid
Leaks (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and
Inspection/Symptom Related Diagnostic Procedures/AF33-5 - Automatic Transaxle/Automatic
Transmission Fluid Leaks) .
* Fluid above level, inspect for contamination of the fluid.
Important: The tranaxle uses T-IV fluid, GM P/N 88900925 (Canadian P/N 22689186). The fluid is
normally red in color. The oil may darken in color with more miles on a vehicle.
11. Inspect the condition of the fluid for the following conditions:
* Excessively dirty with particles in the fluid
- If there are no drivability concerns, replace the fluid. Refer to Transmission Fluid Replacement
(See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement) .
- If drivability concerns are present disassemble and inspect for a cause.
* Burnt smell
- Inspect for the correct fluid. Refer to Fluid Capacity Specifications (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Specifications/Capacity Specifications/AF33-5 Automatic Transaxle) .
- Inspect for conditions that may of cause overheating of the transmission fluid. Refer to
Transmission Overheats (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/AF33-5 Automatic Transaxle/Transmission Overheats) .
- If there are no drivability concerns, replace the fluid. Refer to Transmission Fluid Replacement
(See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal
and Replacement) .
- If drivability concerns are present disassemble and inspect for cause.
- Inspect the transmission oil cooler system for functioning properly. Refer to Transmission Fluid
Cooler Flushing and Flow Test (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/AF33-5
- Automatic Transaxle/Transmission Fluid Cooler Flushing and Flow Test) .
* Black in color
- Disassemble the transaxle and inspect for components that may have over heated.
- Inspect the transmission oil cooler system for functioning properly. Refer to Transmission Fluid
Cooler Flushing and Flow Test (See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/AF33-5
- Automatic Transaxle/Transmission Fluid Cooler Flushing and Flow Test) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection >
AF33-5 Transmission Fluid Checking Procedure > Page 2670
* Milky or white tint in color from coolant or water
- Inspect for failure of the transaxle oil cooler. Refer to Engine Coolant/Water in Transmission (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom
Related Diagnostic Procedures/AF33-5 - Automatic Transaxle/Engine Coolant/Water in
Transmission) .
- Inspect for missing or improperly routed vent hose.
- Inspect for missing fill plug.
12. Install the fluid level indicator.
Notice: Refer to Fastener Notice .
13. Install the fluid indicator bolt.
Tighten the fluid indicator bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection >
AF33-5 Transmission Fluid Checking Procedure > Page 2671
Fluid - A/T: Testing and Inspection 6T70/6T75 Transmission Fluid Checking Procedure
Transmission Fluid Check
This procedure checks both the transmission fluid level, as well as the condition of the fluid itself.
Notice: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in
transmission internal damage.
Important: Ensure the transmission has enough fluid in it to safely start the vehicle without
damaging the transmission. With the vehicle off there must be at least enough fluid to wet the end
of the dipstick bullet. This will ensure that there is enough fluid in the sump to fill the components
once the vehicle is started.
Level Checking Procedure
1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK
(P). 2. Start the engine. 3. Depress the brake pedal and move the shift lever through each gear
range, pausing for about 3 seconds in each range. Then move the shift lever
back to PARK (P).
4. Allow the engine to idle 500-800 rpm for at least 1 minute. Release the brake pedal. 5. Keep the
engine running and observe the transmission fluid temperature (TFT) using the Driver Information
Center or a scan tool.
Important: If the fluid temperature is below the specified range, perform the following procedure to
raise the fluid temperature to the specified range.
6. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or
operate the vehicle until the appropriate TFT is
reached. Drive the vehicle in second gear until the fluid temperature is within the specified range.
Important: Check the transmission fluid level when the TFT is between 180°F and 200°F (82°C and
93°C). The fluid level rises as fluid temperature increases, so it is important to ensure the
transmission fluid temperature is within range.
7. Remove the dipstick and wipe it with a clean rag or paper towel. 8. Inspect the fluid color. The
fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal
particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces
and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the
transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair
the oil cooler, and flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic
Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission) .
9. Install the dipstick and tighten. Wait three seconds and then remove it again.
Important: Always check the fluid level at least twice. Consistent readings are important to
maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent
assembly to ensure it is clean and unclogged.
10. Check both sides of the dipstick and read the lower level.
Important: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within
the crosshatch band is acceptable.
11. Install and remove the dipstick again to verify the reading. 12. If the fluid level is not within the
crosshatch band, and the transmission temperature is between 180°F and 200°F (82°C and 93°C),
add or dranin
fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only
enough fluid to bring the level into the crosshatch band. Important: Do not add more than one pint
(0.5L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take
much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid
level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Transmission
and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/6T70/6T75 - Automatic Transmission/Fluid Leak Diagnosis) .
13. If the fluid level is in the acceptable range, install the dipstick. 14. If the fluid was changed, reset
the transmission oil life monitor if applicable.
Fluid Condition Inspection
* Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal
use, and does not always indicate contamination.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection >
AF33-5 Transmission Fluid Checking Procedure > Page 2672
Important: Fluid that is very dark or black and has a burnt odor usually indicates contamination or
overheating.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal
particles or other debris which may indicate transmission damage. Refer to Road Test (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial
Inspection and Diagnostic Overview/6T70/6T75 - Automatic Transmission) to verify transmission
operation. Change the transmission fluid if no other conditions are found.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic
Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission
Fluid - A/T: Service and Repair 6T70/6T75 - Automatic Transmission
Transmission Fluid Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 2675
Fluid - A/T: Service and Repair AF33-5 - Automatic Transaxle
Transmission Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the drain
plug and drain fluid. Allow at least 5 minutes for the fluid to drain completely. 3. Remove the gasket
from the drain plug and discard.
Installation Procedure
1. Install the new gasket on the drain plug.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug.
Tighten the drain plug to 40 N.m (30 lb ft).
3. Make sure vehicle is level . 4. Remove the fluid level indicator located behind the front transaxle
mount. Refer to Transmission Fluid Level Indicator Replacement (See:
Transmission and Drivetrain/Automatic Transmission/Transaxle/Automatic Transmission Dipstick Dipstick Tube/Service and Repair) .
Notice: Do not remove the 3rd gear anchor band bolt located on top of the transmission for
checking fluid or adding fluid. Removing the bolt will dislocate internal components and require the
transmission to be removed from the vehicle and disassembled for repair.
Important: Dexron(R)III automatic transmission fluid is not compatible with this transaxle. If
Dexron(R)III ATF is used, transaxle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 2676
failure will result. Refer to Sealers, Adhesives, and Lubricants (See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Specifications/Fluid Type Specifications) .
5. Add approximately 3.1 L (3.3 Qt) of GM T-IV fluid to the transaxle , using the fluid level indicator
location.
Important: If the check is necessary at a low oil temperature of 30-40°C (86-104°F), perform check
using the COLD range on the level gage. However, the fluid must be re-checked at the proper fluid
temperature.
6. Start engine and operate vehicle until transaxle fluid temperature reaches 60-70°C (140-158°F).
7. Apply parking brake. 8. Depress brake pedal and move shift lever slowly through all gear ranges
from park (P) to low (L), pausing for about 3 seconds in each range.
Return shift lever to park (P) range at idle condition.
9. Pull level gauge out again and check if fluid level is within the HOT range.
10. If fluid is not within the correct level, adjust accordingly:
1. If fluid is below the HOT range, add enough to bring it up to the correct level. 2. If fluid is above
HOT range, drain excess fluid.
11. Install the fluid level indicator. Refer to Transmission Fluid Level Indicator Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Automatic Transmission Dipstick - Dipstick Tube/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
Rear Differential ...................................................................................................................................
................................................ 500 ml (16.9 ounces)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 2681
Fluid - Differential: Fluid Type Specifications
CARRIER ASSEMBLY -- DIFFERENTIAL (REAR DRIVE MODULE) Axle Lubricant (GM Part No.
U.S. 89021677, in Canada 89021678).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures
Fluid - Differential: Procedures
Rear Axle Lubricant Level Inspection
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair >
Procedures > Page 2684
Fluid - Differential: Removal and Replacement
Rear Axle Lubricant Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TRANSFER CASE FLUID Getrag 760 ................................................................................................
.......................................................................................... 0.8 liters (0.85 quarts) NVG 900 ...............
..............................................................................................................................................................
........................ 500 ml (17.0 oz)
IMPORTANT: To the bottom of the fill hole.
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 2689
Fluid - Transfer Case: Fluid Type Specifications
TRANSFER CASE (POWER TRANSFER UNIT) VERSATRAK Fluid (GM Part No. U.S. 12378514,
in Canada 88901045).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and
Repair > NVG 900 - Transfer Case
Fluid - Transfer Case: Service and Repair NVG 900 - Transfer Case
Transfer Case Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the drain plug (1).
3. Remove the fill plug (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and
Repair > NVG 900 - Transfer Case > Page 2692
1. Clean the drain plug and apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the
threads.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug (1).
Tighten the drain plug to 24 N.m (18 lb ft).
3. Fill the transfer case with synthetic gear lubricant GM P/N 12378514 (Canadian P/N 88901045)
to the bottom of the fill plug, or 540 ml (18.2 oz).
4. Clean the fill plug and apply adhesive GM P/N 12345493 (Canadian P/N 10953488) to the
threads. 5. Install the fill plug (1).
Tighten the fill plug to 15 N.m (11 lb ft).
6. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and
Repair > NVG 900 - Transfer Case > Page 2693
Fluid - Transfer Case: Service and Repair Getrag 760 - Transfer Case
Transfer Case Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the drain plug (2). 3. Remove the fill plug (1).
Installation Procedure
1. Clean the drain plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and
Repair > NVG 900 - Transfer Case > Page 2694
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug (2).
Tighten the drain plug to 39 N.m (29 lb ft).
3. Fill the transfer case with synthetic gear lubricant GM P/N 89021677 (Canadian P/N 89021678)
to the bottom of the fill plug, or 540 ml (18.2 oz). 4. Install the fill plug (1).
Tighten the fill plug to 39 N.m (29 lb ft).
5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2699
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2700
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins
> Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2701
Engine Oil: Technical Service Bulletins Engine - Revised Engine Oil Capacity
INFORMATION
Bulletin No.: 08-06-01-007
Date: March 14, 2008
Subject: Updated Engine Oil Capacity for 3.4L Engine (RPO LNJ)
Models: 2005-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
with 3.4L V6 Engine (VIN F - RPO LNJ)
The purpose of this bulletin is to update the Engine Oil Capacities for the 3.4L V6 Engine (RPO
LNJ) found in the Chevrolet Equinox and Pontiac Torrent.
The engine oil capacity with an oil filter replacement has been revised to 4.3 L (4.5 qts). The
original capacity was 3.8L (4.0 qts). This revision has been made in the Maintenance and
Lubrication, Approximate Fluid Capacities and Engine Mechanical- 3.4L, Engine Mechanical
Specifications sections of SI. This change also applies to the Owners Manual.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
This capacity has been updated by TSB 08-06-01-007.
Engine Oil with Filter ............................................................................................................................
............................................... 4.5 quarts (4.3 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 2704
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE
Look for two things:
1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M.
2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2705
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position the oil drain
pan under the engine oil drain plug.
3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, replace if
necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or
replace oil pan if necessary.
6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair
or replace if necessary.
Installation Procedure
1. Lightly oil the replacement oil filter gasket with clean oil .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2706
Notice: Refer to Component Fastener Tightening Notice .
2. Install the new oil filter. Refer to Maintenance Items .
Tighten the filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug.
Tighten the plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2707
6. Remove the oil fill cap from the rocker arm cover. 7. Fill the engine with new engine oil. Refer to
Approximate Fluid Capacities , Fluid and Lubricant Recommendations and Maintenance Schedule
(North American Emissions) .
8. Install the oil fill cap to the rocker arm cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service
Precautions
Power Steering Fluid: Service Precautions
Using Proper Power Steering Fluid Notice
Notice: When adding fluid or making a complete fluid change, always use the proper power
steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins
> A/C - Refrigerant Recovery/Recycling/Equipment
Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment
Bulletin No.: 08-01-38-001
Date: January 25, 2008
INFORMATION
Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and
Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Attention:
This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C)
Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive
Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be
manufactured in its current state after December 2007 and will be superseded by GE-48800.
The new J2788 standard does not require that GM Dealers replace their ACR2000 units.
ACR2000's currently in use are very capable of servicing today's refrigerant systems when used
correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined
in GM Bulletin 07-01-38-004.
Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800)
will be released as a required replacement for the previously essential ACR2000 (J-43600). This
equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System
Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE)
refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships.
In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination
when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil.
The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush
Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50,
with installation instructions, as a component of the Hybrid essential tool package. Dealerships that
do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore.
Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure.
The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a
Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil.
This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.
Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C
compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It
may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost
Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be
voided.
Warranty Submission Requirements
The Electronically Generated Repair Data (snapshot summary) and printer functions have been
eliminated from the GE-48800. The VGA display and temperature probes were eliminated to
reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge
Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are
submitted for warranty reimbursement. The charge summary data from before and after system
repairs will continue to required, but documented on the repair order only. Both high and low
pressures and the recovery and charge amounts should be noted during the repair and entered on
the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should
continue to be attached to the shops copy of the repair order.
The labor codes that are affected by this requirement are D3000 through D4500.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 2717
Refrigerant: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2718
Refrigerant: Service and Repair
Refrigerant Recovery and Recharging
Tools Required
* J 43600 ACR 2000 Air Conditioning Service Center
* J 45037 A/C Oil Injector
Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove
R-134a from the A/C system, use service equipment that is certified to meet the requirements of
SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the
work area before continuing service. Additional health and safety information may be obtained from
the refrigerant and lubricant manufacturers.
Caution: For personal protection, goggles and gloves should be worn and a clean cloth wrapped
around fittings, valves, and connections when doing work that includes opening the refrigerant
system. If R-134a comes in contact with any part of the body severe frostbite and personal injury
can result. The exposed area should be flushed immediately with cold water and prompt medical
help should be obtained.
Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.
Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through
the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure
is likely to occur. Refer to the manufacturer instructions included with the service equipment before
servicing.
The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers,
recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit
has a display screen that contains the function controls and displays prompts that will lead the
technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered
into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this
vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C
refrigerant.
The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to
recovery and will notify the technician if there are foreign gases present in the A/C system. If
foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.
The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.
Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the
A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the
correct amount.
A/C Refrigerant System Oil Charge Replenishing
If oil was removed from the A/C system during the recovery process or due to component
replacement, the oil must be replenished. Oil can be injected into a charged A/C system using J
45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant
System Capacities.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications
Refrigerant Oil: Specifications
PAG Oil GM P/N 12378526 for United States
PAG Oil GM P/N 88900060 for Canada
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important: Before performing the antilock brake system (ABS) Automated Bleed Procedure, first
perform a manual or pressure bleed of the base brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) . The automated
bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out toward the brake corners.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove all 4 tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction
Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) . Repair or replace components as needed.
4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test . 6.
Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish
communications with the ABS system. Select Special Functions. Select Automated Bleed from the
Special Functions
menu.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed
procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed
procedure:
* If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle , and diagnose the
appropriate DTC.
* If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to
Hydraulic Brake System Bleeding (Manual) ( See: )Hydraulic Brake System Bleeding (Pressure)
(See: ) .
13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14.
Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation . 17. Inspect the brake fluid level. Refer to Master
Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling) .
18. Road test the vehicle while inspecting that the pedal remains high and firm.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 2726
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding
procedure. Add fluid as needed to maintain the proper
level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress
the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant
slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all
air has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 2727
20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
21. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 44894-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster
power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532 ,
or equivalent, to the J 44894-A . 7. Charge the J 29532 , or equivalent, air tank to 175-205 kPa
(25-30 psi). 8. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to
enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake
system in order to ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the
bleeder, then
tighten the bleeder valve.
13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 2728
17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
20. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent,
from the J 44894-A . 21. Remove the J 44894-A from the brake master cylinder reservoir. 22.
Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake
pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External
Leak Inspection) .
2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake
System Automated Bleed Procedure (See: ) .
24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
25. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Brakes and Traction Control/Hydraulic
System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic
Brakes) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 2729
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance-Oil-based substance
- Layered appearance-Silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance-Moisture
- Dark appearance/suspended particles in fluid-Dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Reservoir Replacement (See: Brakes and Traction Control/Hydraulic
System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder
Reservoir Replacement)
* Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction
Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Reservoir Replacement) . Replace the brake master cylinder
reservoir cap diaphragm.
* Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Hose Replacement)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake
System Automated Bleed Procedure > Page 2730
* Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes
/ Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may
have allowed the moisture or particles to enter the hydraulic system.
5. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and
Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
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Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Electrical - Aftermarket Fuse Warning
Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the fuse block cover, push in on the tabs located on the rear of the cover, and lift. To
reinstall, fit together the tabs located on the front of the cover, and push down on the cover until the
tabs on the rear of the cover click into place.
Notice: Spilling liquid on any electrical components on your vehicle may damage it. Always keep
the covers on any electrical component.
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FUSES - USAGE
Fuse 1 ..................................................................................................................................................
........................................................ Cooling Fan 2 Fuse 2 .................................................................
......................................................................................................................................... Cooling Fan
1 Fuse 3 ...............................................................................................................................................
........................................................ Auxiliary Power Fuse 4 ...............................................................
.............................................................................................................................................. Rear
HVAC Fuse 5 .......................................................................................................................................
................................................................................. Spare Fuse 6 .....................................................
..............................................................................................................................................................
..... Spare Fuse 7 .................................................................................................................................
........................................................... Antilock Brake System Fuse 8 .................................................
......................................................................................................................................... Air
Conditioning Clutch Fuse 9 .................................................................................................................
........................................................................... Driver Side Low-Beam Fuse 10 ...............................
.......................................................................................................................................................
Daytime Running Lamp 2 Fuse 11 ......................................................................................................
.............................................................................. Passenger Side High-Beam Fuse 12 ...................
..............................................................................................................................................................
.... Passenger Side Park Lamp Fuse 13 ..............................................................................................
......................................................................................................................... Horn Fuse 14 .............
..............................................................................................................................................................
............... Driver Side Park Lamp Fuse 15 ..........................................................................................
.......................................................................................................................... Starter Fuse 16
............................................................................................................................................ Electronic
Throttle Control, Engine Control Module Fuse 17 ...............................................................................
.................................................................................................................. Emission Device 1 Fuse
18 .........................................................................................................................................................
..................................... Even Coils, Injectors Fuse 19 ........................................................................
....................................................................................................................... Odd Coils, Injectors
Fuse 20 ................................................................................................................................................
................................................. Emission Device 2 Fuse 21 ...............................................................
.......................................................................................................................................................
Spare Fuse 22 .....................................................................................................................................
................................ Powertrain Control Module, Ignition Fuse 23 .....................................................
.....................................................................................................................................................
Transmission Fuse 24 .........................................................................................................................
.................................................................... Mass Airflow Sensor Fuse 25 .........................................
..............................................................................................................................................................
Airbag Display Fuse 26 .......................................................................................................................
............................................................................................... Spare Fuse 27 .....................................
..............................................................................................................................................................
............. Stoplamp
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Engine Compartment Fuse Block > Page 2743
Fuse 28 ................................................................................................................................................
.................................... Passenger Side Low-Beam Fuse 29 ..............................................................
........................................................................................................................... Driver Side
High-Beam Fuse 30 .............................................................................................................................
.......................................................................... Battery Main 3 Fuse 32 ............................................
..............................................................................................................................................................
............ Spare Fuse 33 ........................................................................................................................
.................................................... Engine Control Module, Battery Fuse 34 ........................................
.......................................................................................................................... Transmission Control
Module, Battery Fuse 35 .....................................................................................................................
............................................................................. Trailer Park Lamp Fuse 36 ....................................
..............................................................................................................................................................
......... Front Wiper Fuse 37
............................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Fuse 38 .............................................................................
......................................................................................................................................... Spare Fuse
39 .........................................................................................................................................................
..................................................... Fuel Pump Fuse 40 .......................................................................
......................................................................................................................................... Not Used
Fuse 41 ................................................................................................................................................
.................................................... All-Wheel Drive Fuse 42 .................................................................
................................................................................................................... Regulated Voltage
Control Fuse 43
......................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Fuse 44 .....................................................................
................................................................................................................................................. Spare
Fuse 45 ................................................................................................................................................
................................................ Front, Rear Washer Fuse 48 ..............................................................
.......................................................................................................................................... Rear
Defogger Fuse 49 ................................................................................................................................
............................................... Antilock Brake System Motor Fuse 50 ................................................
.......................................................................................................................................................
Battery Main 2 Fuse 52 .......................................................................................................................
................................................................ Daytime Running Lamps Fuse 53 ......................................
..............................................................................................................................................................
......... Fog Lamps Fuse 54 ...................................................................................................................
......................................................... Climate Control System Blower Fuse 57 ...................................
..............................................................................................................................................................
...... Battery Main 1 Fuse 63 ................................................................................................................
......................................................................... Electric Power Steering
RELAYS - USAGE
Relay 31 ..............................................................................................................................................
......................................................... Ignition Main Relay 46 ...............................................................
.................................................................................................... Air Conditioning Compressor
Clutch Relay 47 ...................................................................................................................................
......................................................................... Powertrain Relay 51 ..................................................
..............................................................................................................................................................
.... Spare Relay 55 ...............................................................................................................................
..................................................................................... Crank Relay 56 ..............................................
..............................................................................................................................................................
........ Fan 1 Relay 58
.....................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Relay 59
..........................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Relay 60 ............................................................................
........................................................................................................................................ Fan 3 Relay
61 .........................................................................................................................................................
........................................................... Fan 2 Relay 62 ........................................................................
.................................................................................................................................... Fuel Pump
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 2744
Fuse: Locations Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
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Engine Compartment Fuse Block > Page 2745
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 2746
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Engine Compartment Fuse Block > Page 2747
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Engine Compartment Fuse Block > Page 2748
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Engine Compartment Fuse Block > Page 2749
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Diagram Information and Instructions > Page 2752
Fuse: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagram Information and Instructions > Page 2753
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Diagram Information and Instructions > Page 2754
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagram Information and Instructions > Page 2756
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 2849
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application
and ID > Underhood Fuse Block
Fuse: Application and ID Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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and ID > Underhood Fuse Block > Page 2852
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and ID > Underhood Fuse Block > Page 2853
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and ID > Underhood Fuse Block > Page 2854
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and ID > Underhood Fuse Block > Page 2855
Fuse: Application and ID Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Locations
Fuse Block: Locations
Front of Vehicle/Engine Compartment Component Views
Front Engine Compartment Components
1 - Fuse Block - Underhood 2 - Battery 3 - Cooling Fan - Left 4 - Cooling Fan - Right
Left Front Engine Compartment Components 2 of 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Locations > Page 2860
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagrams > Diagram Information and Instructions > Page 2865
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 2907
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Diagrams > Diagram Information and Instructions > Page 2908
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Diagrams > Diagram Information and Instructions > Page 2910
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Diagrams > Diagram Information and Instructions > Page 2911
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Diagrams > Diagram Information and Instructions > Page 2912
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Diagrams > Diagram Information and Instructions > Page 2915
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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Diagrams > Diagram Information and Instructions > Page 2918
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 2919
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Diagrams > Diagram Information and Instructions > Page 2921
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Diagrams > Diagram Information and Instructions > Page 2923
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Diagrams > Diagram Information and Instructions > Page 2926
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Diagrams > Diagram Information and Instructions > Page 2927
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Diagrams > Diagram Information and Instructions > Page 2928
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Diagrams > Diagram Information and Instructions > Page 2938
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagrams > Diagram Information and Instructions > Page 2956
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagrams > Diagram Information and Instructions > Page 2957
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2958
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2959
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2960
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2961
Fuse Block: Connector Views
Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2962
Fuse Block - Underhood X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 2963
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2964
Fuse Block - Underhood X2 (Pin 1 To 41)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2965
Fuse Block - Underhood X2 (Pin 42 To C)
Fuse Block - Underhood X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2966
Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2967
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2968
Fuse Block - Instrument Panel X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2969
Fuse Block - Instrument Panel X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2970
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2971
Fuse Block - Instrument Panel X3 (Pin 1 To 38)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2972
Fuse Block - Instrument Panel X3 (Pin 39 To C)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement
Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
Instrument Panel Electrical Center or Junction Block Replacement
Removal Procedure
Important: Record all preset radio stations.
1. Turn the ignition OFF. 2. Remove the screws from the battery cooling box. Remove the battery
cover. 3. Disconnect the negative battery cable. 4. Disconnect the positive battery cable. 5.
Remove the console.
6. Remove the nut holding the following fuse block connectors to the back of the I/P fuse block (4):
* The body connector (1)
* The I/P connector (2)
* The I/P connector (3)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 2975
7. Remove the bolt holding the fuse block into place. 8. Remove the ground wire (1). 9. Remove
the fuse block.
Installation Procedure
Notice: Refer to Fastener Notice.
1. Install the fuse block and attach the ground wire (1) and attach the bolt.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 2976
2. Connect the harness connectors to the back of the I/P fuse block (4).
Tighten the connectors to 4 N.m (35 lb in).
3. Install the console. 4. Connect the positive battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
5. Connect the negative battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
6. Install the battery cooling box cover and install the screws.
Tighten the screws to 2 N.m (18 lb in).
7. Set the radio stations to the preset selections.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 2977
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement
Underhood Electrical Center or Junction Block Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 2978
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket
Replacement
Underhood Electrical Center or Junction Block Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2984
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2985
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2986
Customer TPMS Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2987
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2988
Frequently Asked Questions
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. See: Oil Change
Reminder Lamp/Service and Repair
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated.
^ If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an
open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the
IPC.
2. Ignition OFF, disconnect connector X1 at the ECM. 3. Ignition ON, verify that the MIL is not
illuminated.
^ If the MIL is illuminated, inspect the MIL control circuit for a short to ground. If the circuit tests
normal, replace the IPC.
4. Ignition ON, verify that the MIL illuminates with a 3A fused jumper wire between the MIL control
circuit, ECM terminal X1-68, and ground.
^ If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the ECM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Instrument Cluster Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
ENGINE OIL LIFE SYSTEM
WHEN TO CHANGE ENGINE OIL
Your vehicle has a computer system that lets you know when to change the engine oil and filter.
This is based on engine revolutions and engine temperature, and not on mileage. Based on driving
conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil
life system to work properly, you must reset the system every time the oil is changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. A "CHANGE ENGINE OIL SOON" message will come on. Change your oil as soon
as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best
conditions, the oil life system may not indicate that an oil change is necessary for over a year.
However, your engine oil and filter must be changed at least once a year and at this time the
system must be reset. It is also important to check your oil regularly and keep it at the proper level.
If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since
your last oil change. Remember to reset the oil life system whenever the oil is changed.
HOW TO RESET THE ENGINE OIL LIFE SYSTEM
The Engine Oil Life System calculates when to change your engine oil and filter based on vehicle
use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is
required. If a situation occurs where you change your oil prior to a change engine oil light being
turned on, reset the system.
1. Turn the ignition key to "ON/RUN" with the engine off. 2. Fully press and release the accelerator
pedal three times within five seconds. The engine oil light will flash while the system is resetting. 3.
When the light stops flashing, turn the key to "LOCK/OFF".
If the change engine oil light comes back on and stays on when you start your vehicle, the engine
oil life system has not reset. Repeat the procedure.
WHAT TO DO WITH USED OIL
Used engine oil contains certain elements that may be unhealthy for your skin and could even
cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with
soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing
used engine oil. See the manufacturer's warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil
from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the
ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place
that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a
service station or a local recycling center for help.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Technician Safety Information
Vehicle Lifting: Technician Safety Information
Vehicle Lifting Caution
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Technician Safety Information > Page 3003
Vehicle Lifting: Vehicle Damage Warnings
Vehicle Lifting and Jacking Notice
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 3004
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting-Frame Contact Lift
Front Lift Pads
When lifting the vehicle with a frame-contact lift, place the front lift pads approximately 12.2 in (310
mm) inboard from the front pinchweld flanges.
Rear Lift Pads
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 3005
When lifting the vehicle with a frame-contact lift, place the rear lift pads 10.0 in (255 mm) inboard
from the rear pinchweld flanges.
Vehicle Jacking
Under the Center of the Rear Suspension
Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.
Supporting the Vehicle with Jackstands
Important: Place jackstands ONLY under strong and stable vehicle structures.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM
Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3020
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3021
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3022
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3023
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 3024
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 3025
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service
and Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Notice: Refer to Fastener Notice .
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 3026
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (Standard) (See: Tire Monitoring System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3032
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3033
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3034
Customer TPMS Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3035
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
3036
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor
Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor
Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3049
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3050
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3051
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 3053
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Technical Service Bulletins > Page 3054
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service
and Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Notice: Refer to Fastener Notice .
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Component Information > Technical Service Bulletins > Page 3055
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (Standard) (See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3060
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3061
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Customer TPMS Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3063
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 3064
Frequently Asked Questions
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 10-03-16-001 > Jul > 10 > TPMS System - Service And Re-Learning
Sensor IDs
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3074
2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3075
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3076
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3077
1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 3078
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas in Tires
> Page 3083
degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3088
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3089
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3090
Customer TPMS Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3091
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 3092
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 07-03-10-008B > Aug > 09 > Tires - Slight/Mild Edge Feathering
Information
Tires: Technical Service Bulletins Tires - Slight/Mild Edge Feathering Information
INFORMATION
Bulletin No.: 07-03-10-008B
Date: August 13, 2009
Subject: Information on Slight or Mild Tire Feathering and Recommended Practices (Normal Tire
Wear Condition)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2010 HUMMER H2,
H3 2006-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 07-03-10-008A (Section 03 - Suspension).
This bulletin provides information regarding the normal tire wear condition of slight or mild tire
feathering and recommended practices.
If a vehicle comes into a dealership with a concern of slight or mild feathering-type wear on the
tires, review with the customer their past tire rotation history. Tires should be rotated every 8,000 to
13,000 km (5,000 to 8,000 mi) for applicable vehicles with tires where a tire rotation is possible or
recommended. Refer to Corporate Bulletin Number 05-03-10-015B for information on tire rotation
for vehicles with different front/rear tire/wheel sizes.
SOME TIRE FEATHERING IS A NORMAL PART OF TIRE WEAR AND THROUGH PROPER
TIRE ROTATION AND INFLATION, THIS TIRE WEAR CAN BE MINIMIZED AND TIRE LIFE
MAXIMIZED.
If the customer has not rotated the tires within the last 8,000 to 13,000 km (5,000 to 8,000 mi), a
tire rotation in the modified X-pattern is necessary to clean-up the feathering, rather than placing
the vehicle on the alignment machine.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information
Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information
INFORMATION
Bulletin No.: 00-00-90-002J
Date: January 28, 2009
Subject: Information on Proper Tire Pressure
Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X
Supercede:
This bulletin is being revised to add model years and clarify additional information. Please discard
Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information).
Important:
^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and
no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure
will be rejected.
^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on
the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI).
Recommended inflation pressure is not the pressure printed on tire sidewall.
^ Tires may be over-inflated from the assembly plant due to the mounting process.
^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure change.
^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires
with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a
low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which
specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window
of "usable" pressure values and the warning will be more sensitive to outside temperature changes
during the colder months. As with other cold temperature/tire pressure issues, there is nothing
wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and
set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard.
Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars
and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s
tire placard during PDI.
Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure.
The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct
pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The
tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear
compartment lid.
Tip
^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure increase.
^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more
than 1.6 km (1 mi).
^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for
the low external temperature by adding additional air to the tire during PDI.
^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an
exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating
temperature), the tire pressure should be reset to placard pressure at the cold temperature.
^ The TPM system will work correctly with nitrogen in tires.
^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other
commercially available sealants.
Important:
^ Do not use the tire pressure indicated on the tire itself as a guide.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure Information
> Page 3101
^ Always inspect and adjust the pressure when the tires are cold.
^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire
rotation.
Improper tire inflation may result in any or all of the following conditions:
^ Premature tire wear
^ Harsh ride
^ Excessive road noise
^ Poor handling
^ Reduced fuel economy
^ Low Tire Pressure Monitor (TPM) Light ON
^ Low Tire Pressure Message on the Drivers Information Center (DIC)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3102
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3103
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
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Bulletins > Technical Service Bulletins for Tires: > Page 3104
degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3105
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
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Bulletins > Technical Service Bulletins for Tires: > Page 3106
2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
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Bulletins > Technical Service Bulletins for Tires: > Page 3107
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
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Bulletins > Technical Service Bulletins for Tires: > Page 3108
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
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Bulletins > Technical Service Bulletins for Tires: > Page 3109
1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Tires: > Page 3110
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and
Operation > Tread Wear Indicators Description
Tires: Description and Operation Tread Wear Indicators Description
Tread Wear Indicators Description
Tread Wear Indicators Description
The original equipment tires have tread wear indicators that show when you should replace the
tires.
The location of these indicators are at 60 degree intervals around the outer diameter of the tire.
The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm
(2/32 in).
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Operation > Tread Wear Indicators Description > Page 3113
Tires: Description and Operation Tire Inflation Description
Tire Inflation Description
When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and
tires are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures,
or under-inflated tires, can cause the following conditions:
* Vehicle handling concerns
* Poor fuel economy
* Shortened tire life
* Tire overloading
Inspect the tire pressure when the following conditions apply:
* The vehicle has been sitting at least 3 hours.
* The vehicle has not been driven for more than 1.6 km (1 mi).
* The tires are cool.
Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications
on the tire label. Install the valve caps or the extensions on the valves. The caps or the extensions
keep out dust and water.
The kilopascal (kPa) is the metric term for pressure. The tire pressure may be printed in both
kilopascal (kPa) and psi. One psi equals 6.9 kPa.
Tires with a higher than recommended pressure can cause the following conditions:
* A hard ride
* Tire bruising
* Rapid tread wear at the center of the tire
Tires with a lower than recommended pressure can cause the following conditions:
* A tire squeal on turns
* Hard steering
* Rapid wear and uneven wear on the edge of the tread
* Tire rim bruises and tire rim rupture
* Tire cord breakage
* High tire temperatures
* Reduced vehicle handling
* High fuel consumption
* Soft riding
Unequal pressure on the same axle can cause the following conditions:
* Uneven braking
* Steering lead
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Operation > Tread Wear Indicators Description > Page 3114
* Reduced vehicle handling
Refer to the Tire Placard for specific tire and wheel applications and tire pressures.
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Operation > Tread Wear Indicators Description > Page 3115
Tires: Description and Operation All Seasons Tires Description
All Seasons Tires Description
All Seasons Tires Description
Most Saturn vehicles are equipped with steel belted all-season radial tires as standard equipment.
These tires qualify as snow tires, with a higher than average rating for snow traction than the
non-all season radial tires previously used. Other performance areas, such as wet traction, rolling
resistance, tread life, and air retention, are also improved. This is done by improvements in both
tread design and tread compounds. These tires are identified by an M + S molded in the tire side
wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification
number.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Operation > Tread Wear Indicators Description > Page 3116
Tires: Description and Operation P-Metric Sized Tires Description
P-Metric Sized Tires Description
P-Metric Sized Tires Description
Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement
tires should be of the same tire performance criteria TPC specification number including the same
size, the same load range, and the same construction as those originally installed on the vehicle.
Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best
recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. The
above illustration may not correspond with your vehicle, but is meant as an example.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures
Tires: Procedures
Tire Repair
Tire Repair
Caution:
* Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
* Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
* NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
* NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important:
* NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth.
* NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in).
* NEVER substitute an inner tube for a permissible or non-permissible repair.
* NEVER perform an outside-in tire repair (plug only, on the wheel).
* Every tire must be removed from the wheel for proper inspection and repair.
* Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
* Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep
moisture out. 3. Seal the inner liner with a repair unit to prevent air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3119
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3120
Clean the Injury Channel
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this
step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
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Important: Do not install the repair unit in this step.
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
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Procedures > Page 3122
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads
excessively.
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
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3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
Consult your repair material supplier for the proper stitching tool.
Safety Cage
Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire
safety cage must be used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
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1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - Off Vehicle .
For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA)
1400 K Street, N.W., Suite 900 Washington, DC 20005-2403
Tire Rotation
Tire Rotation
Rotate the tires and wheels at frequent intervals to equalize wear. Refer to Maintenance Schedule
(North American Emissions) . In addition to scheduled rotation, rotate the tire and wheel whenever
uneven tire wear is noticed.
Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in
non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes
regular rotation especially necessary.
Refer to Tire and Wheel Removal and Installation (See: Service and Repair) .
Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then, set
the tire pressure.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair >
Procedures > Page 3125
Tires: Removal and Replacement
Tire Mounting and Dismounting
Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons
alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could
result.
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of
improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air
to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire
changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage
may result in vibration and/or shimmy, and under severe usage lead to wheel cracking.
1. Deflate the tire completely.
Important: Rim-clamp European-type tire changers are recommended.
2. Use the tire changer in order to remove the tire from the wheel. 3. Use a wire brush or coarse
steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats.
Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or
corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound
can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration.
4. Apply an approved Lubricant to the tire bead and the wheel rim. 5. Use the tire changer in order
to install the tire to the wheel.
Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may
break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when
inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads,
deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause
serious personal injury.
6. Inflate the tire to the proper air pressure. 7. Ensure that the locating rings are visible on both
sides of the tire in order to verify that the tire bead is fully seated on the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV)
Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3134
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3135
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 3136
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels >
Page 3141
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3146
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3147
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON >
Page 3148
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3154
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3155
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3156
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 3161
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3166
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3167
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV)
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3172
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
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Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3173
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force
Variation (RFV) > Page 3174
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels > Page 3179
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON
Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3184
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3185
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 3186
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust
Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3196
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3197
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 3198
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum
Wheels > Page 3203
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3208
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 3209
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust
Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and
Operation > Replacement Wheels Description
Wheels: Description and Operation Replacement Wheels Description
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout
* The wheel is bent
* The wheel is cracked
* The wheel is severely rusted
* The wheel is severely corroded
Important: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air
Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s),
install only new Saturn original equipment parts. Installation of used parts or non-Saturn original
equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and
loss of vehicle control resulting in personal injury.
Notice: The use of non-Saturn original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and
Operation > Replacement Wheels Description > Page 3216
Wheels: Description and Operation Steel Wheel Repair Description
Steel Wheel Repair Description
Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from
striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and
uncontrolled heating from welding affects the properties of the material.
Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed
ratings are greatly reduced.
If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Removal Procedure
1. Remove the front brake rotor. Refer to Front Brake Rotor Replacement .
2. Disconnect the wheel speed sensor electrical connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3222
3. Remove the wheel speed sensor electrical connector from the connector bracket.
4. Remove the front wheel drive shaft spindle nut. 5. Remove the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
6. Support the wheel drive shaft with heavy mechanic's wire or equivalent. 7. Remove and discard
the wheel bearing/hub mounting bolts. 8. Remove the wheel bearing/hub assembly from the
steering knuckle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3223
1. Install the wheel bearing/hub assembly to the steering knuckle.
Notice: Refer to Fastener Notice .
2. Install the wheel bearing/hub mounting bolts.
Tighten the bolts to 130 N.m (96 lb ft).
3. Install the wheel drive shaft spindle nut.
Tighten the nut to 205 N.m (151 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3224
4. Install the wheel speed sensor electrical connector to the mounting bracket, if equipped.
5. Connect the wheel speed sensor electrical connector. 6. Install the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
7. Install the front brake rotor. Refer to Front Brake Rotor Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension > Page 3225
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Wheel Drive Shaft Spindle Nut. Tighten the nut to .....................................................................
.............................................................................................................. 205 N.m (151 lb ft).
Rear Wheel Drive Shaft Nut
Important: DO NOT re-use the wheel drive shaft spindle nut. Replace with NEW.
Hand install a new wheel drive shaft spindle nut. Tighten the nut to ...................................................
.................................................................................................................................. 125 N.m (92 lb
ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Nut Hand start the wheel nuts.
Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to
avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification.
Using the J 39544-KIT (proper size torque stick), tighten the wheel nuts in sequence. Tighten to .....
..............................................................................................................................................................
............................. 140 Nm (100 lb ft.)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 3233
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Front
Suspension) .
4. Using the J 43631 , press out the wheel stud from the wheel bearing/hub assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3236
Installation Procedure
1. Install the wheel stud to the wheel bearing/hub assembly from the bearing side of the hub flange.
2. Place flat washers over the wheel stud being installer. 3. Install the wheel nut or a hex head nut
to the wheel stud. 4. Gradually tighten the nut in order to draw the stud into the hub flange until the
head of the wheel stud is fully seated against the hub flange. 5. Remove the nut and flat washers.
6. Install the wheel bearing/hub assembly to the steering knuckle. Refer to Front Wheel Bearing
and Hub Replacement (See: Wheel Bearing/Service
and Repair/Front Suspension) .
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 8. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3237
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the wheel bearing/hub replacement. Refer to Rear Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Rear
Suspension) .
4. Using the J 43631 , press out the wheel stud from the wheel bearing/hub assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service
and Repair > Front Suspension > Page 3238
Installation Procedure
1. Install the wheel stud to the wheel bearing/hub assembly from the bearing side of the hub flange.
2. Place flat washers over the wheel stud being installed. 3. Install the wheel nut or a hex head nut
to the wheel stud. 4. Gradually tighten the nut in order to draw the stud into the hub flange until the
head of the wheel stud is fully seated against the hub flange. 5. Remove the nut and flat washers.
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 7. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions >
Technician Safety Information
Vehicle Lifting: Technician Safety Information
Vehicle Lifting Caution
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions >
Technician Safety Information > Page 3243
Vehicle Lifting: Vehicle Damage Warnings
Vehicle Lifting and Jacking Notice
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page
3244
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting-Frame Contact Lift
Front Lift Pads
When lifting the vehicle with a frame-contact lift, place the front lift pads approximately 12.2 in (310
mm) inboard from the front pinchweld flanges.
Rear Lift Pads
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page
3245
When lifting the vehicle with a frame-contact lift, place the rear lift pads 10.0 in (255 mm) inboard
from the rear pinchweld flanges.
Vehicle Jacking
Under the Center of the Rear Suspension
Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.
Supporting the Vehicle with Jackstands
Important: Place jackstands ONLY under strong and stable vehicle structures.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading
should be less than
................................................................................................................................................... 689
kPa (100 psi).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3251
Compression Check: Testing and Inspection
Engine Compression Test
A compression pressure test of the engine cylinders determines the condition of the rings, the
valves, and the head gasket.
Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse
block. Refer to Electrical Center Identification Views .
1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the
cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open
position. 6. Measure the engine compression, using the following procedure:
1. Firmly install the compression gauge to the spark plug hole. 2. Have an assistant crank the
engine through at least 4 compression strokes in the testing cylinder. 3. Record the readings on the
gauge at each stroke. 4. Disconnect the gauge. 5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
* The lowest reading should not be less than 70 percent of the highest reading.
* No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements:
* When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
* When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, the piston rings may be the cause.
* If the compression improves considerably with the addition of three squirts of oil, the piston rings
may be the cause.
* When the compression is low on the first stroke and does not build up in the following strokes, the
valves may be the cause.
* The addition of oil does not affect the compression, the valves may be the cause.
* When the compression is low on two adjacent cylinders, or coolant is present in the crankcase,
the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain
Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
................................................... 140 N.m (103 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Service and Repair
Camshaft: Service and Repair
Camshaft Rear Bearing Hole Plug Replacement
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) .
2. Remove the camshaft rear bearing hole plug.
Installation Procedure
Important: Inspect plug bore for old sealant. Ensure bore is clean and free of knicks and burs.
1. Apply sealer to the camshaft rear bearing hole plug. Refer to Sealers, Adhesives, and Lubricants
(See: Specifications/Mechanical
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications. 4. Install the engine
flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex
Plate/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
Valve Lifter Replacement
Removal Procedure
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm
Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
2. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement (See: Intake
Manifold/Service and Repair) . 3. Remove the valve rocker arms and pushrods. Refer to Valve
Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and
Repair) .
4. Remove the lifter guide bolts. 5. Remove the lifter guide.
Important: Place the valve lifters in an organized order to ensure that they are installed in the same
location from which they were removed.
6. Remove the lifters.
Installation Procedure
1. Coat the valve lifters using prelube GM P/N 1052367 (Canadian P/N 992869) or the equivalent.
2. Install the valve lifters in their original locations. 3. Install the lifter guide.
Notice: Refer to Fastener Notice .
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the lifter
guide bolt threads and install the bolts.
Tighten the bolts to 10 N.m (89 lb in).
5. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement (See: Rocker Arm Assembly/Service and
Repair) .
6. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement (See: Intake
Manifold/Service and Repair) . 7. Install the valve rocker arm cover. Refer to Valve Rocker Arm
Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm
Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Page 3262
8. Inspect for leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair
Push Rod: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left
Side (See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
2. Remove the rocker arm bolt(s). 3. Remove the valve rocker arm(s) and the pushrod(s).
Installation Procedure
1. Coat the ends of the push rods using prelube GM P/N 1052367 (Canadian P/N 992869) or the
equivalent.
Important: The intake valve push rods measure 146.0 mm (5.75 in) in length. The exhaust valve
push rods measure 152.5 mm (6.0 in) in length.
2. Install the push rods in their original location.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod >
Component Information > Service and Repair > Page 3266
3. Coat the rocker arm friction surfaces using prelube GM P/N 1052367 (Canadian P/N 992869) or
the equivalent.
Important: Shims may be required under the valve rocker arm pedestals if reconditioning has been
performed on the cylinder head or its components.
4. Install the valve rocker arms in their original positions.
Notice: Refer to Fastener Notice .
5. Install the valve rocker arm bolts.
Tighten the bolts to 42 N.m (31 lb ft) .
6. Install the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left
Side (See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
2. Remove the rocker arm bolt(s). 3. Remove the valve rocker arm(s) and the pushrod(s).
Installation Procedure
1. Coat the ends of the push rods using prelube GM P/N 1052367 (Canadian P/N 992869) or the
equivalent.
Important: The intake valve push rods measure 146.0 mm (5.75 in) in length. The exhaust valve
push rods measure 152.5 mm (6.0 in) in length.
2. Install the push rods in their original location.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 3270
3. Coat the rocker arm friction surfaces using prelube GM P/N 1052367 (Canadian P/N 992869) or
the equivalent.
Important: Shims may be required under the valve rocker arm pedestals if reconditioning has been
performed on the cylinder head or its components.
4. Install the valve rocker arms in their original positions.
Notice: Refer to Fastener Notice .
5. Install the valve rocker arm bolts.
Tighten the bolts to 42 N.m (31 lb ft) .
6. Install the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Cylinder Head Assembly/Valve
Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker
Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and
Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting Rod Bearing Clearance
................................................................................................................................. 0.18-0.062 mm
(0.0007-0.017 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Specifications
Connecting Rod: Specifications
Connecting Rod Bore Diameter
................................................................................................................................... 53.962-53.978
mm (2.124-2.125 in) Connecting Rod Bore Out-of-Round
.................................................................................................................................................. 0.008
mm (0.0002 in) Connecting Rod Length - Center to Center
...................................................................................................................... 144.75-144.81 mm
(5.69-5.70 in) Connecting Rod Side Clearance
.......................................................................................................................................... 0.25-0.37
mm (0.010-0.015 in)
Connecting Rod Bearing Cap Bolt
First Pass .............................................................................................................................................
................................................... 20 N.m (15 lb ft) Final Pass .............................................................
............................................................................................................................................ 75
degrees
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications
Crankshaft Main Bearing: Specifications
Crankshaft Main Bearing Cap Bolt/Stud
First Pass .............................................................................................................................................
................................................... 50 N.m (37 lb ft) Final Pass .............................................................
............................................................................................................................................ 77
degrees
Crankshaft Main Bearing Clearance - Except #3
......................................................................................................... 0.019-0.064 mm (0.0008-0.0025
in) Crankshaft Main Bearing Clearance - #3 Thrust Bearing
............................................................................................ 0.032-0.077 mm (0.0012-0.0030 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Crankshaft
Connecting Rod Journal Diameter
....................................................................................................................... 50.768-50.784 mm
(1.9987-1.9994 in) Connecting Rod Journal Out-of-Round
.......................................................................................................................................... 0.005 mm
(0.0002 in) Connecting Rod Journal Taper
.......................................................................................................................................................
0.005 mm (0.0002 in) Connecting Rod Journal Width
.................................................................................................................................... 21.92-22.08
mm (0.863-0.869 in) Crankshaft End Play
................................................................................................................................................
0.060-0.210 mm (0.0024-0.0083 in) Crankshaft Main Bearing Journal Width
......................................................................................................................... 23.9-24.1 mm
(0.941-0.949 in) Crankshaft Main Journal Diameter
...................................................................................................................... 67.239-67.257 mm
(2.6473-2.6483 in) Crankshaft Main Journal Out-of-Round
......................................................................................................................................... 0.005 mm
(0.0002 in) Crankshaft Main Journal Taper
......................................................................................................................................................
0.005 mm (0.0002 in) Crankshaft Rear Flange Runout
........................................................................................................................................................
0.04 mm (0.0016 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement
Engine Block Heater: Service and Repair Coolant Heater Replacement
Coolant Heater Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Cooling System/Service and Repair)Cooling
System Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
2. Remove the coolant heater cord from the heater.
Important: Do not score the surface of the engine block hole when removing the coolant heater.
3. Remove the coolant heater from the block.
Installation Procedure
1. Remove any burrs, sealer, paint or other foreign material from the threads/sealing surface of the
engine block and from the old coolant heater if the
heater is to be reused.
2. If reusing the old coolant heater, apply thread sealant GM P/N 12346004 (Canadian P/N
10953480), or equivalent to the threads.
Notice: Refer to Component Fastener Tightening Notice .
3. Install the coolant heater to the engine block.
Tighten the coolant heater to 50 N.m (37 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 3288
4. Install the coolant heater cord to the heater. 5. Fill the cooling system. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 3289
Engine Block Heater: Service and Repair Coolant Heater Cord Replacement
Coolant Heater Cord Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Disconnect the coolant heater cord (2) from the coolant heater (1).
2. Disconnect the coolant heater cord (1) from the cord retainers (2). 3. Remove the coolant heater
cord (1) from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair > Coolant Heater Replacement > Page 3290
1. Route the coolant heater cord (1) as illustrated, in the engine compartment. 2. Connect the
coolant heater cord (1) to the cord retainers (2) .
3. Connect the coolant heater cord (2) to the coolant heater (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Balancer Bolt
Installation Pass Using the Old Bolt to Ensure the Balancer is Completely Installed
........................................................................... 125 N.m (92 lb ft) First Pass - Install a NEW Bolt
After the Installation Pass and Tighten as Described in the First and Final Passes
............................ 125 N.m (92 lb ft) Final Pass ..................................................................................
..................................................................................................................... 130 degrees
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3294
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Balancer Replacement
Tools Required
* J 39914 Serpentine Belt Tensioner Unloader
* J 41816-A Crankshaft Balancer Remover
* J 29113 Balancer and Crank Sprocket Puller
* J 45059 Angle Meter
* EN 46359 Puller End Protector
Removal Procedure
1. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 2.
Remove the drive belt from the right idler pulley (2). 3. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 4. Remove J 39914 from the drive belt tensioner (8). 5. Raise and
support the vehicle. Refer to Lifting and Jacking the Vehicle . 6. Remove the right front wheel.
Refer to Tire and Wheel Removal and Installation . 7. Remove the wheelhouse liner. Refer to
Engine Splash Shield Replacement .
8. Remove the crankshaft balancer bolt and washer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3295
Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber
type material. The correct installation procedures (with the proper tool) must be followed or
movement of the inertial weight section of the hub will destroy the tuning of the crankshaft
balancer.
Notice: Do NOT use a power-assisted tool with the special tool in order to remove or install this
component. You cannot properly control the alignment of this component using a power-assisted
tool, and this can damage the component.
9. Remove the crankshaft balancer using the J 41816-A along with EN 46359 .
Installation Procedure
1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent, to the keyway of
the crankshaft balancer. 2. Place the crankshaft balancer into position over the key in the
crankshaft.
Notice: Do NOT use a power-assisted tool with the special tool in order to remove or install this
component. You cannot properly control the alignment of this component using a power-assisted
tool, and this can damage the component.
3. Install the J 29113 onto the crankshaft. 4. Rotate the hex nut on the J 29113 to install the
crankshaft balancer onto the crankshaft. 5. Remove the J 29113 from the crankshaft .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3296
Notice: Refer to Fastener Notice .
6. Install the used crankshaft balancer bolt.
Tighten the used crankshaft balancer bolt to 125 N.m (92 lb ft).
7. Remove the used crankshaft balancer bolt. 8. Install a NEW crankshaft balancer bolt.
1. Tighten the crankshaft balancer bolt a first pass to 125 N.m (92 lb ft). 2. Tighten the crankshaft
balancer bolt a final pass to 130 degrees using the J 45059 .
9. Install the wheelhouse liner. Refer to Engine Splash Shield Replacement .
10. Install the right front wheel. Refer to Tire and Wheel Removal and Installation . 11. Lower the
vehicle.
12. Insure the drive belt is properly centered on all the pulleys except the right idler pulley (3). 13.
Using J 39914 rotate the drive belt tensioner away from the drive belt. 14. Install the drive belt to
the right idler pulley (2). 15. Carefully release J 39914 allowing the drive belt tensioner (8) to come
in contact with the drive belt. 16. Remove J 39914 from the drive belt tensioner (8). 17. Inspect the
drive belt to insure the belt is properly centered on all the pulleys (1-8).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston
Piston Diameter - production - cylinder 1-4
............................................................................................................. 91.985-92.003 mm
(3.621-3.622 in) Piston Diameter - service limit - cylinder 1-4
................................................................................................................................. 91.945 mm
(3.619 in) Piston Diameter - production - cylinder 5-6
............................................................................................................... 91.99-92.028 mm
(3.621-3.623 in) Piston Diameter - service limit - cylinder 5-6
................................................................................................................................. 91.945 mm
(3.619 in) Piston Pin Bore Diameter
.................................................................................................................................... 23.005-23.010
mm (0.9057-0.9059 in) Piston Ring Groove Width - First
.................................................................................................................................... 1.23-1.25 mm
(0.048-0.049 in) Piston Ring Groove Width - Second
................................................................................................................................ 1.53-1.55 mm
(0.060-0.061 in) Piston Ring Groove Width - Oil Control
....................................................................................................................... 3.03-3.055 mm
(0.119-0.120 in) Piston to Bore Clearance - production - 1-4
.............................................................................................................. 0.17-0.053 mm
(0.0006-0.0020 in) Piston to Bore Clearance - service limit- 1-4
.................................................................................................................................. 0.093 mm
(0.0036 in) Piston to Bore Clearance - production - 5-6
.......................................................................................................... -0.008-0.048 mm
(-0.0003-0.0018 in) Piston to Bore Clearance - service limit- 5-6
.................................................................................................................................. 0.093 mm
(0.0036 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston Pin Clearance to Connecting Rod Bore - Press Fit
............................................................................... -0.047 to -0.019 mm (-0.0019 to -0.0007 in)
Piston Pin Clearance to Piston Pin Bore
.................................................................................................................. 0.008-0.016 mm
(0.00031-0.00063 in) Piston Pin Diameter
.................................................................................................................................................
22.994-22.997 mm (0.9053-0.9054 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Ring End Gap
First Compression Ring
...................................................................................................................................................
0.15-0.36 mm (0.006-0.014 in) Second Compression Ring
........................................................................................................................................... 0.48-0.74
mm (0.0188-0.0291 in) Oil Control Ring
..........................................................................................................................................................
0.25-0.77 mm (0.0098-0.0303 in)
Piston Ring to Groove Clearance
First Compression Ring
...............................................................................................................................................
0.04-0.086 mm (0.002-0.0033 in) Second Compression Ring
............................................................................................................................................. 0.04-0.08
mm (0.002-0.0031 in) Oil Control Ring
........................................................................................................................................................
0.07-0.095 mm (0.0028-0.0037 in)
Piston Ring Thickness
First Compression Ring
...............................................................................................................................................
1.164-1.190 mm (0.046-0.047 in) Second Compression Ring
....................................................................................................................................... 1.460-1.490
mm (0.0574-0.0586 in) Oil Control Ring - Maximum
...........................................................................................................................................................
2.960 mm (0.116 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 3311
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 3312
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair > Procedures > Page 3313
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Push Rod Replacement
Removal Procedure
1. Remove the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left
Side (See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker Arm Cover Replacement - Right
Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
2. Remove the rocker arm bolt(s). 3. Remove the valve rocker arm(s) and the pushrod(s).
Installation Procedure
1. Coat the ends of the push rods using prelube GM P/N 1052367 (Canadian P/N 992869) or the
equivalent.
Important: The intake valve push rods measure 146.0 mm (5.75 in) in length. The exhaust valve
push rods measure 152.5 mm (6.0 in) in length.
2. Install the push rods in their original location.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly
> Component Information > Service and Repair > Page 3317
3. Coat the rocker arm friction surfaces using prelube GM P/N 1052367 (Canadian P/N 992869) or
the equivalent.
Important: Shims may be required under the valve rocker arm pedestals if reconditioning has been
performed on the cylinder head or its components.
4. Install the valve rocker arms in their original positions.
Notice: Refer to Fastener Notice .
5. Install the valve rocker arm bolts.
Tighten the bolts to 42 N.m (31 lb ft) .
6. Install the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement - Left Side
(See: Valve Cover/Service and Repair/Valve
Rocker Arm Cover Replacement - Left Side) and/or Valve Rocker Arm Cover Replacement - Right
Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side
Valve Rocker Arm Cover Replacement - Left Side
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Disconnect the left side spark plug wires (1) from the retainers (2) .
3. Remove the bolt (2) and the spark plug wire support (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3322
4. Disconnect the positive crankcase ventilation (PCV) foul air pipe (1) from the PCV valve.
Notice: Valve rocker arm cover gasket and sealant must be carefully trimmed away from lower
intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a
severe oil leak.
5. Loosen the valve rocker arm cover bolts.
Important: When removing the valve rocker arm cover, ensure the gasket stays in place attached to
the cylinder head.
6. Remove the valve rocker arm cover.
Bump the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet if the
cover adheres to the cylinder head.
7. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the
cylinder head to the lower intake manifold joints (1). 8. Remove the rocker arm cover gasket. 9.
Clean the sealing surface on the cylinder head with degreaser.
10. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection
(See: Service and Repair/Overhaul) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3323
Installation Procedure
Important: All gasket mating surfaces need to be free of oil and foreign material. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number to use to clean surfaces.
Important: Apply sealant at the cylinder head to lower intake manifold joint. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number.
1. Apply sealant at the cylinder head to lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure the gasket is properly seated in the
groove of the valve rocker arm cover.
Notice: Refer to Fastener Notice .
3. Install the valve rocker arm cover.
Tighten the bolts to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3324
4. Connect the PCV foul air pipe (1) to the PCV valve.
5. Install the spark plug wire support (1) and bolt (2).
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3325
6. Connect the left side spark plug wires (1) to the spark plug wire retainers (2). 7. Install the fuel
injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See: Powertrain
Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3326
Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side
Valve Rocker Arm Cover Replacement - Right Side
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Remove the generator bracket. Refer to Generator Bracket and Engine Lift Bracket
Replacement (LNJ) . 3. Remove the ignition control module bracket from the engine with the
ignition control module and spark plug wires still attached. Position out of
the way. Refer to Ignition Control Module Bracket Replacement .
4. Disconnect the positive crankcase ventilation (PCV) fresh air pipe (1) from the right valve rocker
arm cover.
Notice: Valve rocker arm cover gasket and sealant must be carefully trimmed away from lower
intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a
severe oil leak.
5. Loosen the valve rocker arm cover bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3327
Important: When removing the valve rocker arm cover, ensure the gasket stays in place attached to
the cylinder head.
6. Remove the valve rocker arm cover.
Bump the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet if the
cover adheres to the cylinder head.
7. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the
cylinder head to lower intake manifold joints (1). 8. Remove the valve rocker arm cover gasket. 9.
Clean the sealing surface on the cylinder head with degreaser.
10. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection
(See: Service and Repair/Overhaul) .
Installation Procedure
Important: All gasket mating surfaces need to be free of oil and foreign material. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number to use to clean surfaces.
Important: Apply sealer at the cylinder head to lower intake manifold joint. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number.
1. Apply sealant at the cylinder head to lower intake manifold joints (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Service and Repair > Valve Rocker Arm Cover Replacement - Left Side > Page 3328
2. Install a new gasket to the valve rocker arm cover. Ensure the gasket is properly seated in the
groove of the valve rocker arm cover.
Notice: Refer to Fastener Notice .
3. Install the valve rocker arm cover.
Tighten the bolts to 10 N.m (89 lb in).
4. Connect the PCV fresh air pipe (1) to the right valve rocker arm cover. 5. Install the ignition
control module bracket with the ignition control module and spark plug wired still attached. Refer to
Ignition Control Module
Bracket Replacement .
6. Install the generator bracket. Refer to Generator Bracket and Engine Lift Bracket Replacement
(LNJ) . 7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 08-06-01-022 > Oct > 08 >
Engine - Ticking Noise
Valve Guide: Customer Interest Engine - Ticking Noise
TECHNICAL
Bulletin No.: 08-06-01-022
Date: October 28, 2008
Subject: Tick Type Noise Coming From Engine (Inspect Exhaust Valve Stem to Guide Clearance)
Models: 2006-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Equipped with 3.4L Engine (VIN F - RPO LNJ)
Condition
Some customers may comment that they hear a ticking noise coming from the engine. Some may
describe the noise as sounding like a lifter tick.
Cause
The finish on the exhaust valve stem(s) may have caused excessive wear on the exhaust valve
guide(s) in the cylinder heads. When this occurs, the exhaust valve stem to guide clearance
becomes out of specification and the tick noise is created each time the valve stem comes in
contact with the guide.
Correction
1. Verify that the engine oil level is within the operating range.
2. Verify that the noise in question is not the normal ticking type sound produced by the fuel
injectors.
3. Connect a mechanical oil pressure gauge and verify that the engine has adequate oil pressure.
Refer to SI for additional information if necessary.
4. If the oil pressure is within specification, then remove the left (front) rocker cover and gasket.
Refer to the Valve Rocker Arm Cover Replacement - Left Side in SI.
5. Place shop towels over the rocker arms and push rods to contain engine oil in the next step.
6. Start the engine and allow to idle.
Important:
The following steps only need to be done on the exhaust valves.
7. Using a block of wood or the wooden handle on a hammer, place a side load on cylinder number
2 exhaust valve spring.
^ If the noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and the guide in the cylinder head. Proceed to Step 8.
^ If the noise is NOT reduced or eliminated, then proceed to cylinder number 4 and 6 exhaust valve
springs and apply the same type of side load. If the noise is reduced or eliminated then there is
excessive clearance between an exhaust valve stem and guide in the cylinder head. Proceed to
the next step.
8. Remove the right (rear) rocker cover.
Important:
It may not be possible to apply a side load to the exhaust springs with a piece of wood or hammer
handle because there is less clearance at the rear side of the engine. As a result, the inspection
procedure on the rear side is different than the left (front) side.
9. Remove the rocker arm and push rod from cylinder # 1 exhaust valve.
Important:
With one rocker arm and push rod removed at a time in the next steps the engine will exhibit a
noticeable misfire or rough idle during the test.
10. With shop towels in place to contain any oil, start the engine and allow to idle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 08-06-01-022 > Oct > 08 >
Engine - Ticking Noise > Page 3337
^ If the tick noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and guide in the cylinder head. Proceed to Step 11.
^ If the noise is NOT reduced or eliminated, then reinstall the push rod and rocker arm and tighten
the bolt to specification. Then proceed to cylinder number 3, and if necessary number 5, exhaust
valve and repeat the process. If the noise is reduced or eliminated, then there is excessive
clearance between an exhaust valve stem and guide in the cylinder head. Proceed to the next step.
^ If the tick noise is always present and never is reduced or eliminated when testing all 6 exhaust
valves, then the noise is coming from some other source and it is not necessary to continue with
this bulletin. Refer to SI for additional diagnostic information.
11. Replace any cylinder head that has an exhaust valve stem with excessive clearance to the
guide. It will be necessary to install three new exhaust valves in each cylinder head replaced.
Please note that the exhaust valve part number listed below will have an improved stem finish.
Refer to the Cylinder Head Replacement procedure in SI.
Parts Information
Replacement cylinder heads DO NOT come with any valvetrain components or expansion (freeze)
plugs. When ordering a replacement head, it will also be necessary to order 3 exhaust valves and 2
expansion plugs for each head ordered. The intake valves and "all" springs, caps and locks are
reusable. In addition, new valve stem seals (intake and exhaust) will be needed and are included in
the head gasket kit listed.
Warranty Information
For vehicle repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 08-06-01-022 >
Oct > 08 > Engine - Ticking Noise
Valve Guide: All Technical Service Bulletins Engine - Ticking Noise
TECHNICAL
Bulletin No.: 08-06-01-022
Date: October 28, 2008
Subject: Tick Type Noise Coming From Engine (Inspect Exhaust Valve Stem to Guide Clearance)
Models: 2006-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Equipped with 3.4L Engine (VIN F - RPO LNJ)
Condition
Some customers may comment that they hear a ticking noise coming from the engine. Some may
describe the noise as sounding like a lifter tick.
Cause
The finish on the exhaust valve stem(s) may have caused excessive wear on the exhaust valve
guide(s) in the cylinder heads. When this occurs, the exhaust valve stem to guide clearance
becomes out of specification and the tick noise is created each time the valve stem comes in
contact with the guide.
Correction
1. Verify that the engine oil level is within the operating range.
2. Verify that the noise in question is not the normal ticking type sound produced by the fuel
injectors.
3. Connect a mechanical oil pressure gauge and verify that the engine has adequate oil pressure.
Refer to SI for additional information if necessary.
4. If the oil pressure is within specification, then remove the left (front) rocker cover and gasket.
Refer to the Valve Rocker Arm Cover Replacement - Left Side in SI.
5. Place shop towels over the rocker arms and push rods to contain engine oil in the next step.
6. Start the engine and allow to idle.
Important:
The following steps only need to be done on the exhaust valves.
7. Using a block of wood or the wooden handle on a hammer, place a side load on cylinder number
2 exhaust valve spring.
^ If the noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and the guide in the cylinder head. Proceed to Step 8.
^ If the noise is NOT reduced or eliminated, then proceed to cylinder number 4 and 6 exhaust valve
springs and apply the same type of side load. If the noise is reduced or eliminated then there is
excessive clearance between an exhaust valve stem and guide in the cylinder head. Proceed to
the next step.
8. Remove the right (rear) rocker cover.
Important:
It may not be possible to apply a side load to the exhaust springs with a piece of wood or hammer
handle because there is less clearance at the rear side of the engine. As a result, the inspection
procedure on the rear side is different than the left (front) side.
9. Remove the rocker arm and push rod from cylinder # 1 exhaust valve.
Important:
With one rocker arm and push rod removed at a time in the next steps the engine will exhibit a
noticeable misfire or rough idle during the test.
10. With shop towels in place to contain any oil, start the engine and allow to idle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 08-06-01-022 >
Oct > 08 > Engine - Ticking Noise > Page 3343
^ If the tick noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and guide in the cylinder head. Proceed to Step 11.
^ If the noise is NOT reduced or eliminated, then reinstall the push rod and rocker arm and tighten
the bolt to specification. Then proceed to cylinder number 3, and if necessary number 5, exhaust
valve and repeat the process. If the noise is reduced or eliminated, then there is excessive
clearance between an exhaust valve stem and guide in the cylinder head. Proceed to the next step.
^ If the tick noise is always present and never is reduced or eliminated when testing all 6 exhaust
valves, then the noise is coming from some other source and it is not necessary to continue with
this bulletin. Refer to SI for additional diagnostic information.
11. Replace any cylinder head that has an exhaust valve stem with excessive clearance to the
guide. It will be necessary to install three new exhaust valves in each cylinder head replaced.
Please note that the exhaust valve part number listed below will have an improved stem finish.
Refer to the Cylinder Head Replacement procedure in SI.
Parts Information
Replacement cylinder heads DO NOT come with any valvetrain components or expansion (freeze)
plugs. When ordering a replacement head, it will also be necessary to order 3 exhaust valves and 2
expansion plugs for each head ordered. The intake valves and "all" springs, caps and locks are
reusable. In addition, new valve stem seals (intake and exhaust) will be needed and are included in
the head gasket kit listed.
Warranty Information
For vehicle repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions
Valve Spring: Service Precautions
Valve Springs Can Be Tightly Compressed Caution
Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs.
Personal injury could result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 3347
Valve Spring: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Tools Required
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Removal (See: Service and
Repair/Overhaul) . 2. Remove the spark plug. Refer to Spark Plug Replacement .
Important: Before you remove the valve keys, rotate the engine so that the piston in the cylinder
you are working on is at (TDC) top dead center. This will eliminate the possibility of the valve
accidentally falling inside the cylinder.
3. Install the J 22794 into the spark plug port. Apply compressed air in order to hold the valves in
place.
4. Compress the valve spring with the J 38606 .
5. Remove the valve keys (2). 6. Remove the valve spring cap (3). 7. Remove the valve spring (4).
8. Inspect the valve spring for damage. Replace the spring if it is damaged. 9. Remove the spring
seat/valve stem oil seal (5).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service Precautions > Page 3348
1. Install the valve stem oil seal/spring seat (5).
* Use a suitable driver.
* Press over the valve guide boss.
2. Install the valve spring (4). 3. Install the valve spring cap (3).
4. Compress the valve spring using the J 38606 . 5. Install the valve keys. If necessary, hold the
valve keys in place with grease. 6. Remove the J 38606 in order to release the valve spring. 7.
Ensure that the valve keys are seated. 8. Release the air pressure and remove the J 22794 . 9.
Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Removal (See: Service and
Repair/Overhaul) .
10. Install the spark plug. Refer to Spark Plug Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust
> Component Information > Technical Service Bulletins > Customer Interest for Valve: > 08-06-01-022 > Oct > 08 > Engine
- Ticking Noise
Valve: Customer Interest Engine - Ticking Noise
TECHNICAL
Bulletin No.: 08-06-01-022
Date: October 28, 2008
Subject: Tick Type Noise Coming From Engine (Inspect Exhaust Valve Stem to Guide Clearance)
Models: 2006-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Equipped with 3.4L Engine (VIN F - RPO LNJ)
Condition
Some customers may comment that they hear a ticking noise coming from the engine. Some may
describe the noise as sounding like a lifter tick.
Cause
The finish on the exhaust valve stem(s) may have caused excessive wear on the exhaust valve
guide(s) in the cylinder heads. When this occurs, the exhaust valve stem to guide clearance
becomes out of specification and the tick noise is created each time the valve stem comes in
contact with the guide.
Correction
1. Verify that the engine oil level is within the operating range.
2. Verify that the noise in question is not the normal ticking type sound produced by the fuel
injectors.
3. Connect a mechanical oil pressure gauge and verify that the engine has adequate oil pressure.
Refer to SI for additional information if necessary.
4. If the oil pressure is within specification, then remove the left (front) rocker cover and gasket.
Refer to the Valve Rocker Arm Cover Replacement - Left Side in SI.
5. Place shop towels over the rocker arms and push rods to contain engine oil in the next step.
6. Start the engine and allow to idle.
Important:
The following steps only need to be done on the exhaust valves.
7. Using a block of wood or the wooden handle on a hammer, place a side load on cylinder number
2 exhaust valve spring.
^ If the noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and the guide in the cylinder head. Proceed to Step 8.
^ If the noise is NOT reduced or eliminated, then proceed to cylinder number 4 and 6 exhaust valve
springs and apply the same type of side load. If the noise is reduced or eliminated then there is
excessive clearance between an exhaust valve stem and guide in the cylinder head. Proceed to
the next step.
8. Remove the right (rear) rocker cover.
Important:
It may not be possible to apply a side load to the exhaust springs with a piece of wood or hammer
handle because there is less clearance at the rear side of the engine. As a result, the inspection
procedure on the rear side is different than the left (front) side.
9. Remove the rocker arm and push rod from cylinder # 1 exhaust valve.
Important:
With one rocker arm and push rod removed at a time in the next steps the engine will exhibit a
noticeable misfire or rough idle during the test.
10. With shop towels in place to contain any oil, start the engine and allow to idle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust
> Component Information > Technical Service Bulletins > Customer Interest for Valve: > 08-06-01-022 > Oct > 08 > Engine
- Ticking Noise > Page 3357
^ If the tick noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and guide in the cylinder head. Proceed to Step 11.
^ If the noise is NOT reduced or eliminated, then reinstall the push rod and rocker arm and tighten
the bolt to specification. Then proceed to cylinder number 3, and if necessary number 5, exhaust
valve and repeat the process. If the noise is reduced or eliminated, then there is excessive
clearance between an exhaust valve stem and guide in the cylinder head. Proceed to the next step.
^ If the tick noise is always present and never is reduced or eliminated when testing all 6 exhaust
valves, then the noise is coming from some other source and it is not necessary to continue with
this bulletin. Refer to SI for additional diagnostic information.
11. Replace any cylinder head that has an exhaust valve stem with excessive clearance to the
guide. It will be necessary to install three new exhaust valves in each cylinder head replaced.
Please note that the exhaust valve part number listed below will have an improved stem finish.
Refer to the Cylinder Head Replacement procedure in SI.
Parts Information
Replacement cylinder heads DO NOT come with any valvetrain components or expansion (freeze)
plugs. When ordering a replacement head, it will also be necessary to order 3 exhaust valves and 2
expansion plugs for each head ordered. The intake valves and "all" springs, caps and locks are
reusable. In addition, new valve stem seals (intake and exhaust) will be needed and are included in
the head gasket kit listed.
Warranty Information
For vehicle repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 08-06-01-022 > Oct >
08 > Engine - Ticking Noise
Valve: All Technical Service Bulletins Engine - Ticking Noise
TECHNICAL
Bulletin No.: 08-06-01-022
Date: October 28, 2008
Subject: Tick Type Noise Coming From Engine (Inspect Exhaust Valve Stem to Guide Clearance)
Models: 2006-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Equipped with 3.4L Engine (VIN F - RPO LNJ)
Condition
Some customers may comment that they hear a ticking noise coming from the engine. Some may
describe the noise as sounding like a lifter tick.
Cause
The finish on the exhaust valve stem(s) may have caused excessive wear on the exhaust valve
guide(s) in the cylinder heads. When this occurs, the exhaust valve stem to guide clearance
becomes out of specification and the tick noise is created each time the valve stem comes in
contact with the guide.
Correction
1. Verify that the engine oil level is within the operating range.
2. Verify that the noise in question is not the normal ticking type sound produced by the fuel
injectors.
3. Connect a mechanical oil pressure gauge and verify that the engine has adequate oil pressure.
Refer to SI for additional information if necessary.
4. If the oil pressure is within specification, then remove the left (front) rocker cover and gasket.
Refer to the Valve Rocker Arm Cover Replacement - Left Side in SI.
5. Place shop towels over the rocker arms and push rods to contain engine oil in the next step.
6. Start the engine and allow to idle.
Important:
The following steps only need to be done on the exhaust valves.
7. Using a block of wood or the wooden handle on a hammer, place a side load on cylinder number
2 exhaust valve spring.
^ If the noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and the guide in the cylinder head. Proceed to Step 8.
^ If the noise is NOT reduced or eliminated, then proceed to cylinder number 4 and 6 exhaust valve
springs and apply the same type of side load. If the noise is reduced or eliminated then there is
excessive clearance between an exhaust valve stem and guide in the cylinder head. Proceed to
the next step.
8. Remove the right (rear) rocker cover.
Important:
It may not be possible to apply a side load to the exhaust springs with a piece of wood or hammer
handle because there is less clearance at the rear side of the engine. As a result, the inspection
procedure on the rear side is different than the left (front) side.
9. Remove the rocker arm and push rod from cylinder # 1 exhaust valve.
Important:
With one rocker arm and push rod removed at a time in the next steps the engine will exhibit a
noticeable misfire or rough idle during the test.
10. With shop towels in place to contain any oil, start the engine and allow to idle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 08-06-01-022 > Oct >
08 > Engine - Ticking Noise > Page 3363
^ If the tick noise is reduced or eliminated, then there is excessive clearance between that exhaust
valve stem and guide in the cylinder head. Proceed to Step 11.
^ If the noise is NOT reduced or eliminated, then reinstall the push rod and rocker arm and tighten
the bolt to specification. Then proceed to cylinder number 3, and if necessary number 5, exhaust
valve and repeat the process. If the noise is reduced or eliminated, then there is excessive
clearance between an exhaust valve stem and guide in the cylinder head. Proceed to the next step.
^ If the tick noise is always present and never is reduced or eliminated when testing all 6 exhaust
valves, then the noise is coming from some other source and it is not necessary to continue with
this bulletin. Refer to SI for additional diagnostic information.
11. Replace any cylinder head that has an exhaust valve stem with excessive clearance to the
guide. It will be necessary to install three new exhaust valves in each cylinder head replaced.
Please note that the exhaust valve part number listed below will have an improved stem finish.
Refer to the Cylinder Head Replacement procedure in SI.
Parts Information
Replacement cylinder heads DO NOT come with any valvetrain components or expansion (freeze)
plugs. When ordering a replacement head, it will also be necessary to order 3 exhaust valves and 2
expansion plugs for each head ordered. The intake valves and "all" springs, caps and locks are
reusable. In addition, new valve stem seals (intake and exhaust) will be needed and are included in
the head gasket kit listed.
Warranty Information
For vehicle repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics
Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics
INFORMATION
Bulletin No.: 08-06-01-008A
Date: July 27, 2009
Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of
Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 Vehicles 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add a model year and update the Tool Information.
Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine).
Background
Several aftermarket companies offer laser alignment tools for accessory drive systems that can be
very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges
from $160 - $200.
EN-49228 Laser Alignment Tool - Drive Belt
The GM Tool program has now made available a competitive, simple to use and time-saving laser
tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the
guesswork from proper pulley alignment and may serve to reduce comebacks from:
- Drive Belt Noise
- Accelerated Drive Belt Wear
- Drive Belt Slippage
Instructions
The instructions below are specific only to the truck Gen IV V-8 family of engines. These
instructions are only for illustrative purposes to show how the tool may be used. Universal
instructions are included in the box with the Laser Alignment Tool - Drive Belt.
Caution
- Do not look directly into the beam projected from the laser.
- Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses
help reduce laser beam glare in many circumstances.
- Always use laser safety glasses when using the laser. Laser safety glasses are not designed to
protect eyes from direct laser exposure.
1. Observe and mark the serpentine belt orientation.
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Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page
3369
2. Remove the serpentine belt from the accessory drive system.
3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves
of the pulley, farthest from the front of the
engine.
4. Install the retaining cord around the pulley and to the legs of the tool.
5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the
tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light
beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley
alignment.
- If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly.
- If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the
position of the power steering pulley as required.
- Refer to SI for Power Steering Pulley Removal and Installation procedures.
9. Install the serpentine belt to the accessory drive system in the original orientation.
10. Operate the vehicle and verify that the belt noise concern is no longer present.
Tool Information
Please visit the GM service tool website for pricing information or to place your order for this tool.
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3370
Disclaimer
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 3371
Drive Belt: Service Precautions
Belt Dressing Notice
Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the
composition of the drive belt. Failure to follow this recommendation will damage the drive belt.
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Drive Belt > Component Information > Technical Service Bulletins > Page 3372
Drive Belt: Description and Operation
Drive Belt System Description
The drive belt system consists of the following components:
* The drive belt
* The drive belt tensioner
* The drive belt idler pulley
* The crankshaft balancer pulley
* The accessory drive component mounting brackets
* The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend
backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt
style belt used to drive certain accessory drive components. The drive belts are made of different
types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
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Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Diagnostic Aids
* A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It
may be necessary to spray a small amount of water on the drive belts in order to duplicate the
customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt
pulleys may be the probable solution.
* If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
* A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or
suspension component. Other items of the vehicle may also cause the noise.
* The drive belts will not cause a whine noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be
engine related. This step is to verify that the engine is making the noise. If the engine is not making
the noise do not proceed further with this table. 3. The noise may be an internal engine noise.
Removing the drive belts one at a time and operating the engine for a brief period will verify the
noise is related to the drive belt. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it
can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of
the pulleys may be caused from improper mounting of the accessory drive component, incorrect
installation of the accessory drive component pulley, or the pulley bent inward or outward from a
previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two
or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the
possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for
being bent should include inspecting for a dent or other damage to the pulleys that would prevent
the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a
pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the
drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper
belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal
noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt
tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be
routed properly and may be turning an accessory drive component in the wrong direction. 16.
Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward
or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley
grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive
component for the proper installation procedure for that pulley. 17. This test is to verify that the
pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.
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3377
Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Diagnostic Aids
If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on
the drive belt.
Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt
for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause
the drive belt to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt fall off.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify
the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off.
The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for
cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be
caused from improper mounting of the accessory drive component, incorrect installation of the
accessory drive component pulley, or the pulley bent inward or outward from a previous repair.
Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys.
If a misaligned pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a
dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all
of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to
drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive
belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut ,
spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley
misalignment from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is
correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is
too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any
parts of the engine or body while the engine is operating. There should be sufficient clearance
when the drive belt accessory drive components load varies. The drive belt should not come in
contact with an engine or a body component when snapping the throttle.
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3379
Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Vibration from the engine
operating may cause a body component or another part of the vehicle to make rumbling noise.
Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the
power steering system restricted or the incorrect fluid, or an extra load on the generator. To help
identify an intermittent or an improper condition, vary the loads on the accessory drive components.
The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the
drive belt may be the only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the
drive belts are installed, there might be an accessory drive component with a failure. Varying the
load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that
the symptom is present during diagnosing. Other vehicle components may cause a similar
symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or
vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the
description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When
removing the drive belts the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive
belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt
will not cause the noise. Belt separation is identified by the plys of the belt separating and may be
seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal
condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface
for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt,
nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is
driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump
bearings for smooth operation and excessive play. Compare the water pump with a known good
water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put
extra strain on that accessory component causing it to vibrate.
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3380
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Drive Belt > Component Information > Testing and Inspection > Page 3381
Drive Belt: Service and Repair
Drive Belt Replacement
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 3.
Remove the drive belt from the right idler pulley (2). 4. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 5. Remove J 39914 from the drive belt tensioner (8). 6. Provided the
vehicle will not be raised or lifted to perform additional work. Utilizing a floor jack and a wood block,
support the front of the engine
using the following procedure.
1. Place the wood block between the lift point of the floor jack and the bottom of the engine oil pan.
2. Raise the jack until the wood block comes into contact with the engine oil pan and is capable of
supporting the weight of the engine.
7. If the vehicle is to be raised or lifted in order to perform additional work. Support the engine using
the engine support fixture. Refer to Engine
Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture) .
8. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Engine
Mount/Service and Repair) .
9. Remove the drive belt from the remaining pulleys.
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Installation Procedure
1. Install the drive belt to all the pulleys except the right idler pulley. 2. Install the right engine
mount. Refer to Engine Mount Replacement - Right Side (See: Engine Mount/Service and Repair) .
3. Depending on which method was used to support the engine. Remove the floor jack from under
the engine oil pan or remove the engine support
fixture.
4. Using J 39914 rotate the drive belt tensioner away from the drive belt. 5. Install the drive belt to
the right idler pulley (2). 6. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 7. Remove J 39914 from the drive belt tensioner (8). 8. Inspect the drive
belt to insure the belt is properly centered on all pulleys (1-8). 9. Install the air cleaner assembly.
Refer to Air Cleaner Assembly Replacement .
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Drive Belt Tensioner > Component Information > Testing and Inspection
Drive Belt Tensioner: Testing and Inspection
Drive Belt Tensioner Diagnosis
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Drive Belt Tensioner > Component Information > Testing and Inspection > Page 3386
Drive Belt Tensioner: Service and Repair
Drive Belt Tensioner Replacement
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 2. Remove the
air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
3. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 4.
Remove the drive belt from the right idler pulley (2). 5. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 6. Remove J 39914 from the drive belt tensioner (8).
7. Loosen the drive belt tensioner bolt. 8. Remove the drive belt tensioner and bolt together from
the generator bracket. 9. Separate the bolt from the drive belt tensioner once removed from
vehicle.
Installation Procedure
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1. Install the bolt to the drive belt tensioner .
Notice: Refer to Fastener Notice .
2. Install the drive belt tensioner and bolt as an assembly to the generator bracket.
Tighten the bolt to 50 N.m (37 lb ft).
3. Insure the drive belt is properly centered on all the pulleys except the right idler pulley (3). 4.
Using J 39914 rotate the drive belt tensioner away from the drive belt. 5. Install the drive belt to the
right idler pulley (2). 6. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 7. Remove J 39914 from the drive belt tensioner (8). 8. Inspect the drive
belt to insure the belt is properly centered on all the pulleys (1-8). 9. Install the air cleaner intake
duct. Refer to Air Cleaner Inlet Duct Replacement .
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
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Engine Accessory Bracket > Component Information > Service and Repair
Engine Accessory Bracket: Service and Repair
Engine Lift Bracket Replacement
Removal Procedure
1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Replacement (RPO LNJ)
(See: Cooling System/Thermostat/Service and
Repair)Engine Coolant Thermostat Replacement (RPO LY7) (See: Cooling
System/Thermostat/Service and Repair) .
2. Remove the engine lift bracket bolts. 3. Remove the engine lift bracket from the left cylinder
head.
Installation Procedure
1. Install the engine lift bracket to the left cylinder head.
Notice: Refer to Fastener Notice .
2. Install the engine lift bracket bolts.
Tighten the bolt to 50 N.m (37 lb ft).
3. Install the thermostat housing. Refer to Engine Coolant Thermostat Replacement (RPO LNJ)
(See: Cooling System/Thermostat/Service and
Repair)Engine Coolant Thermostat Replacement (RPO LY7) (See: Cooling
System/Thermostat/Service and Repair) .
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Engine Mount > Component Information > Testing and Inspection
Engine Mount: Testing and Inspection
Engine Mount Inspection
Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of
the fluid is the engine mount, not the engine or accessories.
1. Install the engine support fixture. Refer to Engine Support Fixture (See: Service and
Repair/Removal and Replacement/Engine Support Fixture) . 2. Observe the engine mount while
raising the engine. Raising the engine removes the weight from the engine mount and creates
slight tension on the
rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions:
* The hard rubber is covered with heat check cracks.
* The rubber is separated from the metal plate of the engine mount.
* The rubber is split through the center of the engine mount.
* The engine mount itself is leaking fluid.
4. For engine mount replacement. Refer to the following procedures:
* Engine Mount Replacement - Right Side (See: Service and Repair)
* Engine Mount Bracket Replacement - Right Side (See: Service and Repair)
* Transmission Rear Mount Replacement
* Transmission Mount Replacement - Left Side
* Transmission Rear Mount Bracket Replacement
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Engine Mount: Service and Repair Engine and Transmission Mount Balancing - All Mounts
Engine and Transmission Mount Balancing - All Mounts
Important: Follow the balance procedure in the order listed in the following steps. Powertrain
mounts must be tightened in sequence.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position two floor
jacks with wood blocks under the engine and transmission to support the powertrain assembly.
3. From the engine compartment, loosen the transmission mount to transmission bolts.
4. Loosen the engine mount to intermediate bracket bolts.
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Page 3396
5. Loosen the front transmission mount through bolt. Do not remove.
6. Loosen the rear transmission mount through bolt. Do not remove. 7. Loosen the rear
transmission mount to cradle bolts. 8. Reposition the floor jacks to allow a 1/8 inch gap between
the mount and mount bracket.
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Page 3397
9. Ensure the front transmission mount is centered in the front clevis on the cradle.
Notice: Refer to Fastener Notice .
10. Tighten the transmission mount to transmission bolts using the following sequence:
1. Rear bolt 2. Middle bolt 3. Front Bolt
Tighten the bolts to 50 N.m (37 lb ft).
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Page 3398
11. Tighten the engine mount to intermediate bracket bolts starting with the center bolt.
Tighten the bolts to 50 N.m (37 lb ft).
12. Ensure the rear transmission mount bracket is seated on the transmission housing. 13. Center
the rear transmission mount in the rear cradle clevis. 14. Tighten the rear transmission mount to
cradle bolts.
Tighten the bolts to 50 N.m (37 lb ft).
15. Remove the floor jacks. 16. Shake the powertrain vigorously from front to rear and allow the
powertrain to settle.
17. Tighten the rear transmission mount through bolt.
Tighten the bolts to 110 N.m (81 lb ft).
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Page 3399
18. Tighten the front transmission mount through bolt.
Tighten the bolts to 110 N.m (81 lb ft).
19. Lower the vehicle.
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Page 3400
Engine Mount: Service and Repair Engine Front Mount Replacement
Engine Front Mount Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Place a jack-stand
and a block of wood under the oil pan.
3. Remove the transmission mount bolt.
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Page 3401
4. Remove the transmission mount-to-transmission bolts. 5. Remove the transmission mount from
the vehicle.
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install the transmission mount-to-transmission bolts.
Tighten the bolts to 50 N.m (37 lb ft).
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Page 3402
2. Install the transmission mount bolt.
Tighten the bolts to 110 N.m (81 lb ft).
3. Remove the jack-stand and block of wood under the oil pan. 4. Lower the vehicle.
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Page 3403
Engine Mount: Service and Repair Engine Mount Bracket Replacement - Right
Engine Mount Bracket Replacement - Right Side
Removal Procedure
1. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: ) .
2. Remove the engine mount bracket to engine bolts (1-4). 3. Remove the engine mount bracket
from the engine.
Installation Procedure
1. Position the engine mount bracket to the engine.
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Page 3404
Notice: Refer to Fastener Notice .
2. Install the engine mount bracket to engine bolts (1-4).
1. Tighten the bolts in locations (1) and (2) to 27 N.m (20 lb ft). 2. Tighten the bolts in locations (3)
and (4) to 55 N.m (41 lb ft).
3. Install the right engine mount. Refer to Engine Mount Replacement - Right Side (See: ) .
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Page 3405
Engine Mount: Service and Repair Engine Mount Replacement - Right
Engine Mount Replacement - Right Side
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 2. Support the
engine. Refer to Engine Support Fixture (See: Service and Repair/Removal and
Replacement/Engine Support Fixture) . 3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle .
4. Remove the engine mount to bracket bolts.
5. Remove the engine mount to frame rail nuts. 6. Remove the engine mount from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine and Transmission Mount Balancing - All Mounts >
Page 3406
1. Position the engine mount onto the frame rail studs.
Notice: Refer to Fastener Notice .
2. Install the engine mount to frame rail stud nuts.
Tighten the nuts to 110 N.m (81 lb ft).
3. Install the engine mount to engine mount bracket bolts. Take care when aligning the engine
mount to engine mount bracket bolt holes, while hand
tightening all the bolts.
4. Tighten the engine mount to engine mount bracket bolts.
Tighten the bolts to 50 N.m (81 lb ft).
5. Lower the vehicle. 6. Remove the engine support. Refer to Engine Support Fixture (See: Service
and Repair/Removal and Replacement/Engine Support Fixture) . 7. Install the air cleaner
assembly. Refer to Air Cleaner Assembly Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine and Transmission Mount Balancing - All Mounts >
Page 3407
Engine Mount: Service and Repair Powertrain Mount Balance - Lower Mount
Powertrain Mount Balance - Lower Mount
Important: Follow the balance procedure in the order listed in the following steps. Powertrain
mounts must be tightened in sequence.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Loosen the front mount through bolt. Do not remove.
3. Loosen the rear mount through bolt. Do not remove. 4. Shake the powertrain vigorously from
front to rear and allow the powertrain to settle.
Notice: Refer to Fastener Notice .
5. Tighten the rear motor mount through bolt.
Tighten the bolt to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine and Transmission Mount Balancing - All Mounts >
Page 3408
6. Tighten the front motor mount through bolt.
Tighten the bolt to 110 N.m (81 lb ft).
7. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower
Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Lower
Drive Belt Idler Pulley Replacement - Lower
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 2.
Remove the drive belt from the right idler pulley (2). 3. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 4. Remove J 39914 from the drive belt tensioner (8). 5. Raise and
support the vehicle. Refer to Lifting and Jacking the Vehicle . 6. Remove the right front wheel.
Refer to Tire and Wheel Removal and Installation . 7. Remove the engine splash shield. Refer to
Engine Splash Shield Replacement .
8. Loosen the lower belt idler pulley bolt. 9. Remove the lower belt idler pulley and bolt from the
engine front cover.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower > Page 3413
Notice: Refer to Fastener Notice .
1. Install the lower belt idler pulley and bolt to the engine cover.
Tighten the bolt to 50 N.m (37 lb ft).
2. Install the engine splash shield. Refer to Engine Splash Shield Replacement . 3. Install the right
front wheel. Refer to Tire and Wheel Removal and Installation . 4. Lower the vehicle.
5. Insure the drive belt is properly centered on all the pulleys except the right idler pulley (3). 6.
Using J 39914 rotate the drive belt tensioner away from the drive belt. 7. Install the drive belt to the
right idler pulley (2). 8. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 9. Remove J 39914 from the drive belt tensioner (8).
10. Inspect the drive belt to insure the belt is properly centered on all the pulleys (1-8).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower > Page 3414
Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Left Side
Drive Belt Idler Pulley Replacement - Left Side
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 2. Remove the
air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement . 3. Using J 39914 rotate the
drive belt tensioner (8) to release the tension on the drive belt. 4. Remove the drive belt from the
left idler pulley (3). 5. Carefully release J 39914 to relieve the drive belt tensioner spring tension. 6.
Remove J 39914 from the drive belt tensioner (8).
7. Loosen the left belt idler pulley bolt. 8. Remove the left belt idler pulley and bolt from the engine
front cover.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower > Page 3415
Notice: Refer to Fastener Notice .
1. Install the left belt idler pulley and bolt to the engine front cover.
Tighten the bolt to 50 N.m (37 lb ft).
2. Insure the drive belt is properly centered on all the pulleys except the right idler pulley (3). 3.
Using J 39914 rotate the drive belt tensioner away from the drive belt. 4. Install the drive belt to the
left idler pulley (3). 5. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 6. Remove J 39914 from the drive belt tensioner (8). 7. Inspect the drive
belt to insure the belt is properly centered on all the pulleys (1-8). 8. Install the air cleaner intake
duct. Refer to Air Cleaner Inlet Duct Replacement . 9. Install the air cleaner assembly. Refer to Air
Cleaner Assembly Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower > Page 3416
Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Right Side
Drive Belt Idler Pulley Replacement - Right Side
Tools Required
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 2. Remove the
air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
3. Using J 39914 rotate the drive belt tensioner (8) to release the tension on the drive belt. 4.
Remove the drive belt from the right idler pulley (2). 5. Carefully release J 39914 to relieve the drive
belt tensioner spring tension. 6. Remove J 39914 from the drive belt tensioner (8).
7. Loosen the right belt idler pulley bolt. 8. Remove the right belt idler pulley and bolt from the
generator bracket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Lower > Page 3417
Notice: Refer to Fastener Notice .
1. Install the right belt idler pulley and bolt to the generator bracket.
Tighten the bolt to 50 N.m (37 lb ft).
2. Insure the drive belt is properly centered on all the pulleys except the right idler pulley (3). 3.
Using J 39914 rotate the drive belt tensioner away from the drive belt. 4. Install the drive belt to the
right idler pulley (2). 5. Carefully release J 39914 allowing the drive belt tensioner (8) to come in
contact with the drive belt. 6. Remove J 39914 from the drive belt tensioner (8). 7. Inspect the drive
belt to insure the belt is properly centered on all the pulleys (1-8). 8. Install the air cleaner intake
duct. Refer to Air Cleaner Inlet Duct Replacement . 9. Install the air cleaner assembly. Refer to Air
Cleaner Assembly Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure - @ 1850 RPM
...........................................................................................................................................................
207-241 kPa (30-35 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 3422
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Low or No Oil Pressure
The following conditions may cause low or no oil pressure:
* Low oil level Fill to the full mark on the oil level indicator.
* Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch.
* Incorrect or malfunctioning oil pressure gage Replace the oil pressure gage.
* Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected temperature.
- Install new oil if the oil is diluted.
* A worn or dirty oil pump Clean or replace the oil pump.
* A plugged oil filter Replace the oil filter.
* A loose or plugged oil pickup screen Replace the oil pickup screen.
* A hole in the oil pickup tube Replace the oil pickup tube.
* Excessive bearing clearance Replace the bearings.
* Cracked, porous, or plugged oil gallery Repair or replace the engine block.
* Missing or improperly installed gallery plugs Install or repair the plugs as needed.
* A stuck pressure regulator valve
- Inspect the pressure regulator valve for sticking in the bore.
- Inspect the bore for scoring and burrs.
* A worn or poorly machined camshaft Replace the camshaft.
Oil Pressure Testing
Tools Required
J 25087-C Oil Pressure Tester
If the vehicle has low oil pressure complete the following steps:
1. Inspect the oil level. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base.
Insert the hose in the small hole of the J 25087-C base. Connect the gage to
the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6.
Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil
pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating
temperature before inspecting
the oil pressure. Refer to Engine Mechanical Specifications (See: Specifications/Mechanical
Specifications/Service Limit & General Specifications) .
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump
and/or its components from the lubricating system.
An adequate reading at this time indicates a good pump and the previous low pressure was due to
worn bearings, etc. A low reading while pressing the valve indicates a faulty pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube Replacement
Removal Procedure
1. Remove the oil level indicator (1). 2. Remove the oil level indicator tube bolt (3). 3. Remove the
oil level indicator tube (2).
If you are unable to remove the oil level indicator tube, perform the following steps:
1. Remove the stud in order to allow for lateral movement of the oil level indicator tube. 2. Apply
penetrating oil to the bottom of the oil level indicator tube. 3. Move the oil level indicator tube back
and forth in order to loosen the oil level indicator tube.
Installation Procedure
1. Clean the oil level indicator tube. 2. Apply GM sealant around the oil level indicator tube 12.7
mm (0.50 in) below the bead. Refer to Sealers, Adhesives, and Lubricants (See:
Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for the correct part
number.
3. Install the oil level indicator tube (2) into the engine block.
Notice: Refer to Fastener Notice .
4. Install the oil level indicator tube bolt (3).
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip
Stick Tube > Component Information > Service and Repair > Page 3426
5. Install the oil level indicator (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications
Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications
INFORMATION
Bulletin No.: 11-00-90-001
Date: March 14, 2011
Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for
Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or
Complete Oil Change
Models:
2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with
Duramax(TM) Diesel Engines
GM dexos 1(TM) Information Center Website
Refer to the following General Motors website for dexos 1(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 1(TM) Engine Oil Trademark and Icons
The dexos(TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM)
specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
1(TM) engine oil.
GM dexos 1(TM) Engine Oil Specification
Important General Motors dexos 1(TM) engine oil specification replaces the previous General
Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The
oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains
acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be
used in those older vehicles.
In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine
oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil
specification are as follows:
- To meet environmental goals such as increasing fuel efficiency and reducing engine emissions.
- To promote long engine life.
- To minimize the number of engine oil changes in order to help meet the goal of lessening the
industry's overall dependence on crude oil.
dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the
following benefits:
- Further improve fuel economy, to meet future corporate average fuel economy (CAFE)
requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits
throughout the life of the oil.
- More robust formulations for added engine protection and aeration performance.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3431
- Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life
has been depleted.
- Reduce the duplication of requirements for a large number of internal GM engine oil
specifications.
International Lubricants Standardization and Approval Committee (ILSAC)
GF-5 Standard
In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval
Committee (ILSAC) standard called GF-5, was introduced in October 2010.
- There will be a corresponding API category, called: SN Resource Conserving. The current GF-4
standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos
1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a
statistically significant increase in fuel economy versus the Sequence VIB test that was used for
GF-4.
- It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard.
However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification.
- Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API
will begin licensing marketers during October 2010, to produce and distribute GF-5 certified
products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils.
Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy
Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than
doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed
CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet
these future requirements, all aspects of vehicle operation are being looked at more critically than
ever before.
New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel
economy include direct injection, cam phasing, turbocharging and active fuel management (AFM).
The demands of these new technologies on engine oil also are taken into consideration when
determining new oil specifications. AFM for example can help to achieve improved fuel economy.
However alternately deactivating and activating the cylinders by not allowing the intake and
exhaust valves to open contributes to additional stress on the engine oil.
Another industry trend for meeting tough fuel economy mandates has been a shift toward lower
viscosity oils.
dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs:
SAE 0W-20, 5W-20, 0W-30 and 5W-30.
Using the right viscosity grade oil is critical for proper engine performance. Always refer to the
Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being
serviced.
GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals
To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the
GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000
mile (4,830 km) recommendation.
The dexos (TM) specification, with its requirements for improved oil robustness, compliments the
GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle.
If all GM customers with GM Oil Life System equipped vehicles would use the system as intended,
GM estimates that more than 100 million gallons of oil could be saved annually.
GM dexos 2(TM) Information Center Website
Refer to the following General Motors website for dexos 2(TM) information about the different
licensed brands that are currently available: http://www.gmdexos.com
GM dexos 2(TM) Engine Oil Trademark and Icons
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3432
The dexos (TM) specification and trademarks are exclusive to General Motors, LLC.
Only those oils displaying the dexos (TM) trademark and icon on the front label meet the
demanding performance requirements and stringent quality standards set forth in the dexos
(TM)specification.
Look on the front label for any of the logos shown above to identify an authorized, licensed dexos
2(TM) engine oil.
GM dexos 2(TM) Engine Oil Specification
- dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010
vehicles, regardless of where the vehicle was manufactured.
- dexos 2(TM) is the recommended service fill oil for European gasoline engines.
Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting
specification CJ-4.
- dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and
replaces GM-LL-B-025 and GM-LL-A-025.
- dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on
certain chemical components to prolong catalyst life and protect expensive emission reduction
systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum
performance longer.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 3433
Engine Oil: Technical Service Bulletins Engine - Revised Engine Oil Capacity
INFORMATION
Bulletin No.: 08-06-01-007
Date: March 14, 2008
Subject: Updated Engine Oil Capacity for 3.4L Engine (RPO LNJ)
Models: 2005-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
with 3.4L V6 Engine (VIN F - RPO LNJ)
The purpose of this bulletin is to update the Engine Oil Capacities for the 3.4L V6 Engine (RPO
LNJ) found in the Chevrolet Equinox and Pontiac Torrent.
The engine oil capacity with an oil filter replacement has been revised to 4.3 L (4.5 qts). The
original capacity was 3.8L (4.0 qts). This revision has been made in the Maintenance and
Lubrication, Approximate Fluid Capacities and Engine Mechanical- 3.4L, Engine Mechanical
Specifications sections of SI. This change also applies to the Owners Manual.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
This capacity has been updated by TSB 08-06-01-007.
Engine Oil with Filter ............................................................................................................................
............................................... 4.5 quarts (4.3 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 3436
Engine Oil: Fluid Type Specifications
ENGINE OIL TYPE
Look for two things:
1.GM6094M Your vehicle's engine requires oil meeting GM Standard GM6094M.
2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or
thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements
should also have the starburst symbol on the container. This symbol indicates that the oil has been
certified by the American Petroleum Institute (API). You should look for this information on the oil
container, and use only those oils that are identified as meeting GM Standard GM6094M and have
the starburst symbol on the front of the oil container.
NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the
American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the
recommended oil can result in engine damage not covered by your warranty.
GM Goodwrench oil meets all the requirements for your vehicle.
If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is
recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will
provide easier cold starting and better protection for your engine at extremely low temperatures.
ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst
symbol that meet GM Standard GM6094M are all you will need for good performance and engine
protection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 3437
Engine Oil: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position the oil drain
pan under the engine oil drain plug.
3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, replace if
necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or
replace oil pan if necessary.
6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair
or replace if necessary.
Installation Procedure
1. Lightly oil the replacement oil filter gasket with clean oil .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 3438
Notice: Refer to Component Fastener Tightening Notice .
2. Install the new oil filter. Refer to Maintenance Items .
Tighten the filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug.
Tighten the plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 3439
6. Remove the oil fill cap from the rocker arm cover. 7. Fill the engine with new engine oil. Refer to
Approximate Fluid Capacities , Fluid and Lubricant Recommendations and Maintenance Schedule
(North American Emissions) .
8. Install the oil fill cap to the rocker arm cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance
Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance
INFORMATION
Bulletin No.: 07-06-01-016B
Date: July 27, 2009
Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin
Number 07-06-01-016A (Section 06 - Engine/Propulsion System).
Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is
not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R)
oil filters directly from GMSPO.
Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the
most recent parts information to ensure the correct part number filter is installed when replacing oil
filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been
discovered in some aftermarket parts systems. Always ensure the parts you install are from a
trusted source. Improper oil filter installation may result in catastrophic engine damage.
Refer to the appropriate Service Information (SI) installation instructions when replacing any oil
filter and pay particular attention to procedures for proper cartridge filter element alignment. If the
diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise
or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number
02-00-89-002I (Information for Dealers on How to Submit a Field Product Report).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 3444
Oil Filter: Service and Repair
Engine Oil and Oil Filter Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Position the oil drain
pan under the engine oil drain plug.
3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, replace if
necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or
replace oil pan if necessary.
6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair
or replace if necessary.
Installation Procedure
1. Lightly oil the replacement oil filter gasket with clean oil .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 3445
Notice: Refer to Component Fastener Tightening Notice .
2. Install the new oil filter. Refer to Maintenance Items .
Tighten the filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug.
Tighten the plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Technical Service Bulletins > Page 3446
6. Remove the oil fill cap from the rocker arm cover. 7. Fill the engine with new engine oil. Refer to
Approximate Fluid Capacities , Fluid and Lubricant Recommendations and Maintenance Schedule
(North American Emissions) .
8. Install the oil fill cap to the rocker arm cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair
Oil Filter Adapter: Service and Repair
Oil Filter Adapter and Bypass Valve Assembly Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the oil filter.
Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair) .
3. Remove the oil filter adapter bolts (2). 4. Remove the oil filter adapter (1) and gasket from the
engine block.
5. Remove the oil filter bypass hole plug.
Important: Do not pry against the threads in the oil filter bypass hole when removing the bypass
valve.
6. Insert a flat-bladed tool into the oil filter bypass hole and force the bypass valve out in order to
remove the bypass valve.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter >
Component Information > Service and Repair > Page 3450
1. Install the oil filter bypass valve (1) to the proper depth.
Notice: Refer to Fastener Notice .
2. Install the oil filter bypass hole plug.
Tighten the plug to 19 N.m (14 lb ft).
3. Install the oil filter adapter (1) and gasket to the engine block. 4. Install the oil filter adapter bolts
(2).
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the oil filter. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and
Repair) . 6. Lower the vehicle. 7. Fill the engine with NEW engine oil. Refer to Approximate Fluid
Capacities , Fluid and Lubricant Recommendations and Maintenance
Schedule (North American Emissions) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications
Oil Pan: Specifications
Oil Pan Bolt ..........................................................................................................................................
....................................................... 25 N.m (18 lb ft) Oil Pan Side Bolt ...............................................
......................................................................................................................................... 50 N.m (37
lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 3454
Oil Pan: Service and Repair
Oil Pan Replacement
Tools Required
J 39505 Torque Wrench Adapter
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection . 2. Install the engine support fixture. Refer to Engine Support Fixture (See: Service
and Repair/Removal and Replacement/Engine Support Fixture) . 3. Raise and support the vehicle.
Refer to Lifting and Jacking the Vehicle . 4. Remove the air conditioning (A/C) compressor. Refer to
Compressor Replacement (LNJ) Compressor Replacement (LY7) .
5. Remove the engine-to-transaxle brace bolts (1, 2). 6. Remove the engine-to-transaxle brace (3).
7. Remove the starter. Refer to Starter Motor Replacement (LNJ) Starter Motor Replacement (LY7)
. 8. If equipped with all wheel drive (AWD), remove the transfer case . Refer to Transfer Case
Replacement 9. If equipped with front wheel drive (FWD), remove the intermediate shaft. Refer to
Intermediate Shaft Replacement .
10. Drain the engine oil and remove the oil filter. Refer to Engine Oil and Oil Filter Replacement
(See: Engine Oil/Service and Repair) .
11. Remove the oil pan side bolts. 12. Remove the oil pan sealing surface bolts. 13. Remove the oil
pan. 14. Clean the oil pan and the engine block gasket surface.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 3455
Important: Provided the rear main bearing cap and engine front cover have not been removed and
provided the sealant on either side of the rear main bearing cap and engine front cover has not
been disturbed, it may not be necessary to apply additional sealant in these locations.
1. Apply sealer to both sides of the crankshaft rear main bearing cap (1) and where the engine front
cover meets the engine block. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number. Press the sealer into the gap using a putty knife.
2. Install the oil pan gasket. 3. Install the oil pan.
Notice: Refer to Fastener Notice .
4. Install the oil pan flange bolts.
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the oil pan side bolts.
Using J 39505 torque the bolts to 50 N.m (37 lb ft).
6. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service
and Repair) . 7. If equipped with FWD, install the intermediate shaft. Refer to Intermediate Shaft
Replacement . 8. If equipped with AWD, install the transfer case . Refer to Transfer Case
Replacement . 9. Install the starter. Refer to Starter Motor Replacement (LNJ) Starter Motor
Replacement (LY7) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine >
Component Information > Specifications > Page 3456
10. Install the engine-to-transaxle brace (3). 11. Install the engine-to-transaxle brace bolts (1, 2).
Tighten the bolts to 50 N.m (37 lb ft).
12. Install the A/C compressor. Refer to Compressor Replacement (LNJ) Compressor
Replacement (LY7) . 13. Lower the vehicle. 14. Remove the engine support fixture. 15. Connect
the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . 16. Fill
the engine with new engine oil. Refer to Approximate Fluid Capacities , Fluid and Lubricant
Recommendations , and Maintenance Schedule
(North American Emissions) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 3460
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure Switch (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor >
Component Information > Service and Repair > Page 3464
1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Specifications/Mechanical
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure - @ 1850 RPM
...........................................................................................................................................................
207-241 kPa (30-35 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine
Oil Pressure > Component Information > Specifications > Page 3469
Engine Oil Pressure: Testing and Inspection
Oil Pressure Diagnosis and Testing
Low or No Oil Pressure
The following conditions may cause low or no oil pressure:
* Low oil level Fill to the full mark on the oil level indicator.
* Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch.
* Incorrect or malfunctioning oil pressure gage Replace the oil pressure gage.
* Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected temperature.
- Install new oil if the oil is diluted.
* A worn or dirty oil pump Clean or replace the oil pump.
* A plugged oil filter Replace the oil filter.
* A loose or plugged oil pickup screen Replace the oil pickup screen.
* A hole in the oil pickup tube Replace the oil pickup tube.
* Excessive bearing clearance Replace the bearings.
* Cracked, porous, or plugged oil gallery Repair or replace the engine block.
* Missing or improperly installed gallery plugs Install or repair the plugs as needed.
* A stuck pressure regulator valve
- Inspect the pressure regulator valve for sticking in the bore.
- Inspect the bore for scoring and burrs.
* A worn or poorly machined camshaft Replace the camshaft.
Oil Pressure Testing
Tools Required
J 25087-C Oil Pressure Tester
If the vehicle has low oil pressure complete the following steps:
1. Inspect the oil level. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base.
Insert the hose in the small hole of the J 25087-C base. Connect the gage to
the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6.
Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil
pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating
temperature before inspecting
the oil pressure. Refer to Engine Mechanical Specifications (See: Specifications/Mechanical
Specifications/Service Limit & General Specifications) .
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump
and/or its components from the lubricating system.
An adequate reading at this time indicates a good pump and the previous low pressure was due to
worn bearings, etc. A low reading while pressing the valve indicates a faulty pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement
Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement
INFORMATION
Bulletin No.: 00-06-01-026C
Date: February 03, 2010
Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to include additional model years. Please discard
Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine).
When replacing an engine due to internal damage, extreme care should be taken when transferring
the intake manifold to the new Goodwrench service engine long block. Internal damage may result
in the potential discharge of internal engine component debris in the intake manifold via broken
pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the
engine, the technician should carefully inspect all of the cylinder head intake ports to see if the
valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently
bent, internal engine component debris will be present to varying degrees in the intake port of the
cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold
should be replaced. This replacement is required due to the complex inlet runner and plenum
configuration of most of the intake manifolds, making thorough and complete component cleaning
difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake
manifold removed from an engine with deposits of internal engine component debris may result in
the ingestion of any remaining debris into the new Goodwrench service engine. This may cause
damage or potential failure of the new service engine.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Page 3474
Intake Manifold: Specifications
Lower Intake Manifold Bolt - Center
First Pass .............................................................................................................................................
.................................................... 7 N.m (62 lb in) Final Pass .............................................................
................................................................................................................................ 13 N.m (115 lb in)
Lower Intake Manifold Bolt - Corner
First Pass .............................................................................................................................................
................................................ 13 N.m (115 lb in) Final Pass .............................................................
.................................................................................................................................. 25 N.m (18 lb ft)
Throttle Body Bolt/Stud ........................................................................................................................
..................................................... 10 N.m (89 lb in)
Upper Intake Manifold Bolt/Stud ..........................................................................................................
...................................................... 25 N.m (18 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement
Intake Manifold: Service and Repair Lower Intake Manifold Replacement
Lower Intake Manifold Replacement
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Cooling System/Service and Repair)Cooling
System Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
2. Remove the upper intake manifold. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
3. Remove the heater inlet pipe. Refer to Heater Inlet Pipe Replacement (RPO LNJ) (See: Cooling
System/Coolant Line/Hose/Service and Repair
)Heater Inlet Pipe Replacement (RPO LY7) (See: Cooling System/Coolant Line/Hose/Service and
Repair) .
4. Disconnect the radiator inlet hose from the thermostat housing. Refer to Radiator Inlet Hose
Replacement (LNJ Chevrolet) (See: Cooling
System/Radiator Hose/Service and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See:
Cooling System/Radiator Hose/Service and Repair)Radiator Inlet Hose Replacement (LY7).
5. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
6. Remove the lower intake manifold bolts. 7. Remove the lower intake manifold from the engine. 8.
If replacing the lower intake manifold, remove the thermostat and housing. Refer to Engine Coolant
Thermostat Replacement (RPO LNJ) (See:
Cooling System/Thermostat/Service and Repair)Engine Coolant Thermostat Replacement (RPO
LY7) (See: Cooling System/Thermostat/Service and Repair) .
9. Remove the rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement
(See: Camshaft, Lifters and Push Rods/Rocker
Arm Assembly/Service and Repair) .
10. Remove the lower intake manifold gaskets.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3477
Important: *
All gasket mating surfaces must remain free of oil and foreign material. Refer to Sealers,
Adhesives, and Lubricants (See: Specifications/Mechanical Specifications/Sealers, Adhesives, and
Lubricants) for the correct part number to use to clean surfaces.
* Do not apply room temperature vulcanizing (RTV) sealer to the engine block prior to the
installation of the manifold gaskets. RTV sealer is not to be placed under the lower intake manifold
gaskets.
1. Install the lower intake manifold gaskets. 2. Install the rocker arms and push rods. Refer to Valve
Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm
Assembly/Service and Repair) .
3. Install the lower intake manifold seals. 4. With the seals in place, apply a small drop 8-10 mm
(0.31-0.39 in) of RTV sealer (1). Refer to Sealers, Adhesives, and Lubricants (See:
Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for the correct part
number.
5. Install the lower intake manifold to the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3478
Notice: Maximum gasket performance is achieved when using new fasteners, which contain a
thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied
to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY
reduce gasket sealing capability.
Notice: Refer to Fastener Notice .
Important: *
All lower intake manifold bolts need to be clean, free of foreign materials, and reused only if new
bolts are unavailable. Refer to Sealers, Adhesives, and Lubricants (See: Specifications/Mechanical
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number. Apply to the old
intake manifold bolt threads.
* Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure
proper torque distribution.
* Lower intake manifold bolts in locations (6) and (7) should be torqued to specification using a
crows foot type tool.
6. Install the lower intake manifold bolts.
1. Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass. 2.
Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final
pass. 3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the
final pass.
7. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement . 8.
Connect the radiator inlet hose to the thermostat housing. Refer to Radiator Inlet Hose
Replacement (LNJ Chevrolet) (See: Cooling
System/Radiator Hose/Service and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See:
Cooling System/Radiator Hose/Service and Repair)Radiator Inlet Hose Replacement (LY7).
9. Install the heater inlet pipe. Refer to Heater Inlet Pipe Replacement (RPO LNJ) (See: Cooling
System/Coolant Line/Hose/Service and Repair
)Heater Inlet Pipe Replacement (RPO LY7) (See: Cooling System/Coolant Line/Hose/Service and
Repair) .
10. Install the upper intake manifold. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
11. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Cooling System/Service and Repair)Cooling System
Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3479
Intake Manifold: Service and Repair Upper Intake Manifold Replacement
Upper Intake Manifold Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Release the clamp (1) from the brake booster vacuum hose connection. 3. Disconnect the brake
booster vacuum hose (2) from the intake manifold.
4. Disconnect the left side spark plug wires (1) from the retainers (2) and from the spark plugs.
Refer to Spark Plug Wire Replacement . 5. Remove the ignition control module bracket from the
engine with the ignition control module and spark plug wires still attached. Position out of
the way. Refer to Ignition Control Module Bracket Replacement .
6. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3480
7. Remove the heater outlet pipe nut (4) from the upper intake manifold. 8. Remove the heater
outlet pipe nuts (2) and bolt (3) from the throttle body. 9. Position the heater outlet pipe out of the
way without disconnecting the heater hoses.
10. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe
Replacement . 11. Remove the positive crankcase ventilation (PCV) foul air hose. Refer to Positive
Crankcase Ventilation Hose/Pipe/Tube Replacement (See:
Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve
Hose/Service and Repair) .
12. Loosen but do not completely remove the generator attachment bolt most near the intake
manifold.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3481
13. Remove the generator brace nut (2). 14. Remove the generator brace (1).
15. Remove the upper intake manifold bolts (4, 5). 16. Remove the spark plug wire retainer (3). 17.
Remove the upper intake manifold (2). 18. Remove the upper intake manifold gaskets (1). 19. If
replacing the upper intake manifold complete the following steps:
1. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure
Sensor Replacement . 2. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve
Replacement . 3. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to
Evaporative Emission Canister Purge Solenoid Valve Replacement
.
4. Remove the throttle body. Refer to Throttle Body Assembly Replacement . 5. Remove the fuel
injector sight shield studs. Refer to Fuel Injector Sight Shield Replacement (See: Powertrain
Management/Fuel Delivery and
Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3482
1. Install the upper intake manifold gaskets (1) to the lower intake manifold and install the fir tree
retainers to retain the upper intake manifold gasket
position.
2. Install the upper intake manifold (2). 3. Install the spark plug wire retainer (3).
Notice: Refer to Fastener Notice .
4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the bolt threads. Install the
upper intake manifold bolts (4, 5).
Tighten the bolts to 25 N.m (18 lb ft).
5. If the upper manifold was replaced, complete the following steps:
1. Install the fuel injector sight shield studs. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and
Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Install the throttle body. Refer to Throttle Body Assembly Replacement . 3. Install the EVAP
purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
4. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement . 5. Install MAP
sensor. Refer to Manifold Absolute Pressure Sensor Replacement .
6. Install the generator brace (1). 7. Install the generator brace nut (2).
Tighten the nut to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3483
8. Fully insert the generator attachment bolt most near the intake manifold.
Tighten the bolt to 25 N.m (18 lb ft).
9. Install the PCV foul air hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement (See: Powertrain Management/Emission
Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair) .
10. Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .
11. Position the heater outlet pipe to the throttle body and the upper intake manifold. 12. Install the
heater outlet pipe nuts (2) to the throttle body.
Tighten the nut to 10 N.m (89 lb in).
13. Install the heater outlet pipe bolt (3) to the throttle body.
Tighten the bolt to 10 N.m (89 lb in).
14. Install the heater outlet pipe nut (4) to the upper intake manifold.
Tighten the nut to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Service and Repair > Lower Intake Manifold Replacement > Page 3484
15. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement . 16. Install the
ignition control module bracket . Refer to Ignition Control Module Bracket Replacement .
17. Connect the left side spark plug wires (1) to the spark plugs and to the spark plug wire
retainers. Refer to Spark Plug Wire Replacement .
18. Connect the brake booster vacuum hose (2) to the intake manifold. 19. Install the clamp (1) to
the brake booster vacuum hose connection. 20. Install the fuel injector sight shield. Refer to Fuel
Injector Sight Shield Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal
Crankshaft Main Bearing Seal: Customer Interest Engine - Oil Leaks from Crankshaft Rear Main
Seal
Bulletin No.: 05-06-01-019F
Date: October 02, 2007
TECHNICAL
Subject: Engine Oil Leak at Crankshaft Rear Main Oil Seal (Install Revised Crankshaft Rear Main
Oil Seal Using Revised Rear Main Seal Installer and Remover Tools)
Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn)
with 2.8L, 3.1L, 3.4L, 3.5L, 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W,
X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2
or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG)
Supercede:
This bulletin is being revised to add an Important statement on proper seal installation. Please
discard Corporate Bulletin Number 05-06-01-019E (Section 06 - Engine/Propulsion System).
This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine
VINs and RPOs may have carried over to other new model year engines and may no longer be a
60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the following
information is correct before using this bulletin:
Year of vehicle (e.g. N = 1992)
V6 Engine Liter size (e.g. 3.4L)
VIN CODE (e.g. X)
RPO (e.g. LQ1)
If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found
under the models listed above, then this bulletin applies to that engine. If one or more of the
vehicle's information can NOT be found under the models listed above, then this bulletin does NOT
apply.
This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1).
Condition
Some customers may comment on external oil leakage.
Correction
Before replacement of the new design crankshaft rear main oil seal, be sure the PCV system is
operating correctly. The new seal described below comes with a protective nylon sleeve already
installed in the seal. This sleeve assures that the seal is installed in the correct direction and also
protects the seal from getting damaged during installation. Do not remove the protective sleeve
from the seal; if removed, the installation tool (EN48108) will not work.
A new design crankshaft rear main oil seal and installation tool (EN-48108) has been released.
This seal incorporates features that improve high mileage durability. Replace the crankshaft rear
main oil seal with the new design rear main oil seal, P/N 12592195, using the following service
procedures.
Tools Required
TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR
THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3494
EN-48108 Rear Main Oil Seal Installation Tool
This tool has a unique design to allow the technician to easily install the rear main seal squarely to
the correct depth and direction. Before proceeding with installation, review the above illustration to
become familiar with the components shown in the illustration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3495
EN-48672 rear Main Oil Seal Remover Tool
This tool has a unique design to allow the technician to easily remove the rear main seal without
nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal,
review the above illustration to become familiar with the following components:
Removal Plate
Threaded Adjustment Pins and Jam Nuts
Force Screw
# 2 Self Drill Screws 38 mm (1.5 in) long 8 needed
Extreme Pressure Lubricant
Removal Procedure
Remove the transmission. Refer to Transmission Replacement in SI or the appropriate Service
Manual.
Remove the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate
Service Manual.
Install the removal plate (2) and both threaded adjustment pins and jam nuts (1) into the back of
the crankshaft flange and secure the plate with adjustment pins and jam nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3496
Install # 2 Self Drill Screws 38 mm (1.5 in) long, eight needed, (1) and tighten down flush to the
plate.
Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J
23444-A, provided in the tool kit.
Install the force screw (1) and back off both jam nuts (2) and continue to turn the force screw (1)
into the removal plate to remove the seal from the crankshaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3497
Once the seal is removed from the crankshaft, remove and save all eight screws and discard the
old seal.
Clean the crankshaft sealing surface with a clean, lint free towel. Inspect the lead-in edge of the
crankshaft for burrs or sharp edges that could damage the rear main oil seal. Remove any burrs or
sharp edges with crocus cloth or equivalent before proceeding.
Installation Procedure
Do not remove the protective nylon sleeve from the new rear main seal prior to installation. The
EN-48108 is designed to install the rear main seal with the protective sleeve in place. Never apply
or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal.
Align the mandrel dowel pin (EN-48108) to the dowel pin hole in the crankshaft. Refer to the above
illustration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3498
Using a large flat-bladed screwdriver, tighten the two mandrel screws to the crankshaft. Ensure that
the mandrel is snug to the crankshaft hub. Refer to the above illustration.
Different types (styles) of rear main seals were used in production in different model years, engines
and manufacturing facilities. As a result, the NEW style rear main seal that you will be installing
may have a different appearance or shape than the one removed. Regardless of what type of seal
was removed and what side was facing outside the engine, the new seal must be installed as
described. Upon close inspection of the outer lip on the new seal, the words this side out" will be
seen. This side of the seal must be facing OUTSIDE the engine when correctly installed. While this
may seem backwards, it is correct. In addition, the protective nylon (plastic) sleeve that the seal is
mounted on in the package was designed so that the seal can only be installed in the proper
direction when using the installation tool described in the following steps.
Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel. The
seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an
error proof, seal will fit only one way onto the mandrel. Refer to the above illustration.
Before installing the outer drive drum, bearing, washer and the drive nut onto the threaded shaft,
apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3499
Install the outer drive drum onto the mandrel (EN-481 08). Install the bearing, washer and the drive
nut onto the threaded shaft. Refer to the above illustration.
Using a wrench, turn the drive nut on the mandrel (EN-48108), which will push the seal into the
engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block.
Refer to the above illustration.
Loosen and remove the drive nut, washer, bearing and drive drum. Discard the protective nylon
sleeve.
Verify that the seal has seated properly.
Use a flat-bladed screwdriver to remove the two attachment screws from the mandrel and remove
the mandrel from the crankshaft hub. Refer to the above illustration.
Install the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service
Manual.
Install the transmission. Refer to Transmission Replacement in SI or the appropriate Service
Manual.
Inspect for proper fluid levels.
Inspect for leaks.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal:
> 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3500
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal
Crankshaft Main Bearing Seal: All Technical Service Bulletins Engine - Oil Leaks from Crankshaft
Rear Main Seal
Bulletin No.: 05-06-01-019F
Date: October 02, 2007
TECHNICAL
Subject: Engine Oil Leak at Crankshaft Rear Main Oil Seal (Install Revised Crankshaft Rear Main
Oil Seal Using Revised Rear Main Seal Installer and Remover Tools)
Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn)
with 2.8L, 3.1L, 3.4L, 3.5L, 3.9L 60 Degree V6 Engine (VINs D, E, F, J, K, L, M, N, R, S, T, V, W,
X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1 or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2
or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8, LZG)
Supercede:
This bulletin is being revised to add an Important statement on proper seal installation. Please
discard Corporate Bulletin Number 05-06-01-019E (Section 06 - Engine/Propulsion System).
This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine
VINs and RPOs may have carried over to other new model year engines and may no longer be a
60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the following
information is correct before using this bulletin:
Year of vehicle (e.g. N = 1992)
V6 Engine Liter size (e.g. 3.4L)
VIN CODE (e.g. X)
RPO (e.g. LQ1)
If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found
under the models listed above, then this bulletin applies to that engine. If one or more of the
vehicle's information can NOT be found under the models listed above, then this bulletin does NOT
apply.
This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1).
Condition
Some customers may comment on external oil leakage.
Correction
Before replacement of the new design crankshaft rear main oil seal, be sure the PCV system is
operating correctly. The new seal described below comes with a protective nylon sleeve already
installed in the seal. This sleeve assures that the seal is installed in the correct direction and also
protects the seal from getting damaged during installation. Do not remove the protective sleeve
from the seal; if removed, the installation tool (EN48108) will not work.
A new design crankshaft rear main oil seal and installation tool (EN-48108) has been released.
This seal incorporates features that improve high mileage durability. Replace the crankshaft rear
main oil seal with the new design rear main oil seal, P/N 12592195, using the following service
procedures.
Tools Required
TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR
THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3506
EN-48108 Rear Main Oil Seal Installation Tool
This tool has a unique design to allow the technician to easily install the rear main seal squarely to
the correct depth and direction. Before proceeding with installation, review the above illustration to
become familiar with the components shown in the illustration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3507
EN-48672 rear Main Oil Seal Remover Tool
This tool has a unique design to allow the technician to easily remove the rear main seal without
nicking the crankshaft sealing surface when removing the seal. Before proceeding with removal,
review the above illustration to become familiar with the following components:
Removal Plate
Threaded Adjustment Pins and Jam Nuts
Force Screw
# 2 Self Drill Screws 38 mm (1.5 in) long 8 needed
Extreme Pressure Lubricant
Removal Procedure
Remove the transmission. Refer to Transmission Replacement in SI or the appropriate Service
Manual.
Remove the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate
Service Manual.
Install the removal plate (2) and both threaded adjustment pins and jam nuts (1) into the back of
the crankshaft flange and secure the plate with adjustment pins and jam nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3508
Install # 2 Self Drill Screws 38 mm (1.5 in) long, eight needed, (1) and tighten down flush to the
plate.
Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J
23444-A, provided in the tool kit.
Install the force screw (1) and back off both jam nuts (2) and continue to turn the force screw (1)
into the removal plate to remove the seal from the crankshaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3509
Once the seal is removed from the crankshaft, remove and save all eight screws and discard the
old seal.
Clean the crankshaft sealing surface with a clean, lint free towel. Inspect the lead-in edge of the
crankshaft for burrs or sharp edges that could damage the rear main oil seal. Remove any burrs or
sharp edges with crocus cloth or equivalent before proceeding.
Installation Procedure
Do not remove the protective nylon sleeve from the new rear main seal prior to installation. The
EN-48108 is designed to install the rear main seal with the protective sleeve in place. Never apply
or use any oil, lubricants or sealing compounds on the crankshaft rear main oil seal.
Align the mandrel dowel pin (EN-48108) to the dowel pin hole in the crankshaft. Refer to the above
illustration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3510
Using a large flat-bladed screwdriver, tighten the two mandrel screws to the crankshaft. Ensure that
the mandrel is snug to the crankshaft hub. Refer to the above illustration.
Different types (styles) of rear main seals were used in production in different model years, engines
and manufacturing facilities. As a result, the NEW style rear main seal that you will be installing
may have a different appearance or shape than the one removed. Regardless of what type of seal
was removed and what side was facing outside the engine, the new seal must be installed as
described. Upon close inspection of the outer lip on the new seal, the words this side out" will be
seen. This side of the seal must be facing OUTSIDE the engine when correctly installed. While this
may seem backwards, it is correct. In addition, the protective nylon (plastic) sleeve that the seal is
mounted on in the package was designed so that the seal can only be installed in the proper
direction when using the installation tool described in the following steps.
Install the rear main seal (1), with the protective nylon sleeve attached (2), onto the mandrel. The
seal, if properly installed, will center on a step that protrudes from the center of the mandrel. As an
error proof, seal will fit only one way onto the mandrel. Refer to the above illustration.
Before installing the outer drive drum, bearing, washer and the drive nut onto the threaded shaft,
apply a small amount of the Extreme Pressure Lubricant J 23444-A, provided in the tool kit.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3511
Install the outer drive drum onto the mandrel (EN-481 08). Install the bearing, washer and the drive
nut onto the threaded shaft. Refer to the above illustration.
Using a wrench, turn the drive nut on the mandrel (EN-48108), which will push the seal into the
engine block bore. Turn the wrench until the drive drum is snug and flush against the engine block.
Refer to the above illustration.
Loosen and remove the drive nut, washer, bearing and drive drum. Discard the protective nylon
sleeve.
Verify that the seal has seated properly.
Use a flat-bladed screwdriver to remove the two attachment screws from the mandrel and remove
the mandrel from the crankshaft hub. Refer to the above illustration.
Install the engine flywheel. Refer to Engine Flywheel Replacement in SI or the appropriate Service
Manual.
Install the transmission. Refer to Transmission Replacement in SI or the appropriate Service
Manual.
Inspect for proper fluid levels.
Inspect for leaks.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main
Bearing Seal: > 05-06-01-019F > Oct > 07 > Engine - Oil Leaks from Crankshaft Rear Main Seal > Page 3512
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Technical Service Bulletins > Page 3513
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Oil Seal Replacement
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and
Drivetrain/Flex Plate/Service and Repair) . 2. Remove the crankshaft rear oil seal. Refer to
Crankshaft Rear Oil Seal Removal (See: Service and Repair/Overhaul) .
Installation Procedure
1. Install the rear main seal. Refer to Crankshaft Rear Oil Seal Installation (See: Service and
Repair/Overhaul) . 2. Install the engine flywheel. Refer to Engine Flywheel Replacement (See:
Transmission and Drivetrain/Flex Plate/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023
> Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal
Front Crankshaft Seal: Customer Interest Engine - Oil Leaks From Front Crankshaft Seal
Bulletin No.: 07-06-01-023
Date: December 05, 2007
TECHNICAL
Subject: 60 Degree V6 Engine Oil Leak at Crankshaft Front Oil Seal (Use New Crankshaft Front Oil
Seal Installer Tool EN-48869)
Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn)
with 2.8L, 3.1L, 3.4L, 3.5L or 3.9L 60 Degree V6 Engine
(VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1
or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8,
LZG)
This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1).
This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine
VINs and RPOs may have carried over to other new model year engines and may no longer be a
60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the
information shown is correct before using this bulletin.
If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found
under the models listed above, then this bulletin applies to that engine. If one or more of the
vehicle's information can NOT be found under the models listed above, then this bulletin does NOT
apply.
Condition
Some customers may comment on external oil leakage.
Correction
Before replacement of the crankshaft front oil seal, be sure the PCV system is operating correctly.
Tools Required
TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR
THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023
> Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3522
The EN-48869 has a unique design to allow the technician to easily install the front crankshaft seal
squarely to the correct depth and direction. Before proceeding with installation, review the
illustration to become familiar with the tool.
Removal Procedure
Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI.
Use care not to damage the engine front cover or nick the crankshaft.
Remove the crankshaft front oil seal (1) using a suitable tool.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023
> Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3523
Lubricate the inside of the crankshaft front oil seal (1) with clean engine oil. Then install the seal to
the installer body (2).
Align the oil seal and installer body (1) with the engine front cover and crankshaft.
Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J
23444-A, provided in the tool kit, to the force screw.
Install the drive nut (4) onto the threaded force screw shaft (5), washer (3), and bearing (2). Then
install to the installer body (1) and tighten the force screw to the crankshaft by hand.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023
> Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3524
Using a wrench, turn the drive nut on the threaded force screw shaft (2), this will push the seal into
the engine front cover.
Continue to turn the drive nut (2) with the wrench until the installer body (1) is snug and flush
against the engine front cover.
Loosen and remove the drive nut from the threaded force screw shaft, washer, bearing, and
installer body. Verify that the seal has seated properly, flush against front cover flange (1).
Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI.
Inspect for proper fluid levels.
Inspect for leaks.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 07-06-01-023
> Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3525
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: >
07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal
Front Crankshaft Seal: All Technical Service Bulletins Engine - Oil Leaks From Front Crankshaft
Seal
Bulletin No.: 07-06-01-023
Date: December 05, 2007
TECHNICAL
Subject: 60 Degree V6 Engine Oil Leak at Crankshaft Front Oil Seal (Use New Crankshaft Front Oil
Seal Installer Tool EN-48869)
Models: 1986-2008 GM Passenger Cars and Light Duty Trucks (including Saturn)
with 2.8L, 3.1L, 3.4L, 3.5L or 3.9L 60 Degree V6 Engine
(VINs D, E, F, J, K, L, M, N, R, S, T, V, W, X, Z, 1, 3, 8, 9, W, R - RPOs LG6, LA1, LNJ, LG8, LL1
or LX9, L82, LL2, LB8, LHO, LG5, LB6, LE2 or LQ1, LH7, LC1, L44, LZ4, LZE, LZ9, LGD, LZ8,
LZG)
This bulletin does not apply to 2004-2007 Saturn VUE models with 3.5L DOHC V6 Engine (VIN 4 RPO L66) or 2005-2008 Cadillac CTS with 2.8L HFV6 Engine (VIN T - RPO LP1).
This bulletin only applies to 60 degree V6 engines. Some of the discontinued 60 degree V6 engine
VINs and RPOs may have carried over to other new model year engines and may no longer be a
60 degree V6 engine. So this bulletin may not apply. It is very important to verify that the
information shown is correct before using this bulletin.
If ALL the information from the vehicle (year, size, VIN Code, RPO) you're working on can be found
under the models listed above, then this bulletin applies to that engine. If one or more of the
vehicle's information can NOT be found under the models listed above, then this bulletin does NOT
apply.
Condition
Some customers may comment on external oil leakage.
Correction
Before replacement of the crankshaft front oil seal, be sure the PCV system is operating correctly.
Tools Required
TOOLS WERE SHIPPED TO YOUR DEALERSHIPS. IF YOU HAVE NOT RECEIVED THEM OR
THEY ARE LOST, PLEASE CALL GM SPECIAL SERVICE TOOLS AT 1-800-GM-TOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: >
07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3531
The EN-48869 has a unique design to allow the technician to easily install the front crankshaft seal
squarely to the correct depth and direction. Before proceeding with installation, review the
illustration to become familiar with the tool.
Removal Procedure
Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI.
Use care not to damage the engine front cover or nick the crankshaft.
Remove the crankshaft front oil seal (1) using a suitable tool.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: >
07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3532
Lubricate the inside of the crankshaft front oil seal (1) with clean engine oil. Then install the seal to
the installer body (2).
Align the oil seal and installer body (1) with the engine front cover and crankshaft.
Before installing the force screw, apply a small amount of the Extreme Pressure Lubricant J
23444-A, provided in the tool kit, to the force screw.
Install the drive nut (4) onto the threaded force screw shaft (5), washer (3), and bearing (2). Then
install to the installer body (1) and tighten the force screw to the crankshaft by hand.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: >
07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3533
Using a wrench, turn the drive nut on the threaded force screw shaft (2), this will push the seal into
the engine front cover.
Continue to turn the drive nut (2) with the wrench until the installer body (1) is snug and flush
against the engine front cover.
Loosen and remove the drive nut from the threaded force screw shaft, washer, bearing, and
installer body. Verify that the seal has seated properly, flush against front cover flange (1).
Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in SI.
Inspect for proper fluid levels.
Inspect for leaks.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: >
07-06-01-023 > Dec > 07 > Engine - Oil Leaks From Front Crankshaft Seal > Page 3534
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft
Seal > Component Information > Technical Service Bulletins > Page 3535
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal Replacement
Tools Required
J 35468 Cover Aligner and Seal Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine
front cover or the crankshaft. 3. Inspect the crankshaft, the crankshaft balancer and the engine
front cover for wear and/or damage. Replace the components as necessary.
Installation Procedure
1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. 2.
Install the crankshaft front oil seal using the J 35468 and a suitable tool. 3. Install the crankshaft
balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic
Balancer - Crankshaft
Pulley/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve Stem Oil Seal and Valve Spring Replacement
Tools Required
* J 22794 Spark Plug Port Adapter
* J 38606 Valve Spring Compressor
Removal Procedure
1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Removal (See: Service and
Repair/Overhaul) . 2. Remove the spark plug. Refer to Spark Plug Replacement .
Important: Before you remove the valve keys, rotate the engine so that the piston in the cylinder
you are working on is at (TDC) top dead center. This will eliminate the possibility of the valve
accidentally falling inside the cylinder.
3. Install the J 22794 into the spark plug port. Apply compressed air in order to hold the valves in
place.
4. Compress the valve spring with the J 38606 .
5. Remove the valve keys (2). 6. Remove the valve spring cap (3). 7. Remove the valve spring (4).
8. Inspect the valve spring for damage. Replace the spring if it is damaged. 9. Remove the spring
seat/valve stem oil seal (5).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 3539
1. Install the valve stem oil seal/spring seat (5).
* Use a suitable driver.
* Press over the valve guide boss.
2. Install the valve spring (4). 3. Install the valve spring cap (3).
4. Compress the valve spring using the J 38606 . 5. Install the valve keys. If necessary, hold the
valve keys in place with grease. 6. Remove the J 38606 in order to release the valve spring. 7.
Ensure that the valve keys are seated. 8. Release the air pressure and remove the J 22794 . 9.
Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Removal (See: Service and
Repair/Overhaul) .
10. Install the spark plug. Refer to Spark Plug Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations > Page 3544
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure Switch (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sensor > Component Information > Service and Repair > Page 3548
1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Specifications/Mechanical
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
................................................... 140 N.m (103 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Timing Chain and Sprocket Replacement
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing
Cover/Service and Repair) .
2. Remove the camshaft sprocket bolt. 3. Remove the camshaft sprocket and timing chain.
4. Remove the crankshaft sprocket.
5. Remove the timing chain dampener bolts. 6. Remove the timing chain dampener.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3556
1. Install the crankshaft sprocket . 2. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or
the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain dampener.
Notice: Refer to Fastener Notice .
4. Install the timing chain dampener bolts.
Tighten the bolt to 21 N.m (15 lb ft).
5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain
dampener (1). 6. Hold the camshaft sprocket with the timing chain hanging down and install the
timing chain to the crankshaft gear. 7. Align the timing mark on the camshaft gear (4) with the
timing mark on top of the timing chain dampener (3).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Page 3557
8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket. 9. Draw the
camshaft sprocket onto the camshaft using the mounting bolt.
10. Coat the crankshaft and camshaft sprocket with engine oil.
Tighten the bolt to 140 N.m (103 lb ft).
11. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing
Cover/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Dampener Bolt ..............................................................................................................
....................................................... 21 N.m (15 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component
Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
^ Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain
dampener (1).
^ Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the
crankshaft gear.
^ Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain
dampener (3).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine Front Cover Bolt
Large Bolt ............................................................................................................................................
.................................................. 55 N.m (41 lb ft) Medium Bolt ...........................................................
............................................................................................................................... 55 N.m (41 lb ft)
Small Bolt ............................................................................................................................................
.................................................. 27 N.m (20 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3567
Timing Cover: Service and Repair
Engine Front Cover Replacement
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection . 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 3.
Install the engine support fixture. Refer to Engine Support Fixture (See: Service and
Repair/Removal and Replacement/Engine Support Fixture) . 4. Remove the drive belt. Refer to
Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service
and Repair) . 5. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static
Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling
System Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 7. Remove the
crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
8. Remove the lower belt idler pulley. Refer to Drive Belt Idler Pulley Replacement - Lower (See:
Drive Belts, Mounts, Brackets and
Accessories/Idler Pulley/Service and Repair/Drive Belt Idler Pulley Replacement - Lower) .
9. Remove the engine oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil
Pan/Service and Repair) .
10. Lower the vehicle. 11. Remove the left belt idler pulley. Refer to Drive Belt Idler Pulley
Replacement - Left Side (See: Drive Belts, Mounts, Brackets and
Accessories/Idler Pulley/Service and Repair/Drive Belt Idler Pulley Replacement - Left Side) .
12. Remove the right engine mount bracket bolts (2-4). 13. Remove the right engine mount bracket
(1). 14. Remove the water pump. Refer to Water Pump Replacement (RPO LNJ) (See: Water
Pump/Service and Repair)Water Pump Replacement (RPO
LY7) (See: Water Pump/Service and Repair) .
15. Remove the thermostat bypass hose adapter. Refer to Thermal Bypass Fitting Replacement
(See: Cooling System/Coolant Line/Hose/Service and
Repair) .
16. Remove the radiator outlet hose from the engine front cover. Refer to Radiator Outlet Hose
Replacement (LNJ) (See: Cooling System/Radiator
Hose/Service and Repair)Radiator Outlet Hose Replacement (LY7) (See: Cooling System/Radiator
Hose/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3568
17. Remove the engine front cover bolts (2-4). 18. Remove the engine front cover (1).
19. Remove the engine front cover gasket (1). 20. Clean the engine block and front cover gasket
sealing surfaces.
Installation Procedure
1. Apply sealer to the lower tabs of the engine front cover gasket. Refer to Sealers, Adhesives, and
Lubricants (See: Specifications/Mechanical
Specifications/Sealers, Adhesives, and Lubricants) for the correct part number. Uniformly apply the
sealer to both sides of the gasket lower tabs with the sealant bead being no less than 5.0 mm (0.20
in) wide as shown. Torque front cover immediately after installation of sealer coated gasket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3569
2. Install the gasket (1) to the engine block positioning the gasket on the locating pins (2).
3. Install the engine front cover (1) to the engine block aligning the cover with the locating pins.
Notice: Refer to Fastener Notice .
4. Install the engine front cover bolts (3, 4).
Tighten the bolts to 55 N.m (41 lb ft).
5. Install the engine front cover bolts (2).
Tighten the bolts to 27 N.m (20 lb ft).
6. Install the radiator outlet hose to the engine front cover. Refer to Radiator Outlet Hose
Replacement (LNJ) (See: Cooling System/Radiator
Hose/Service and Repair)Radiator Outlet Hose Replacement (LY7) (See: Cooling System/Radiator
Hose/Service and Repair) .
7. Install the thermostat bypass hose adapter. Refer to Thermal Bypass Fitting Replacement (See:
Cooling System/Coolant Line/Hose/Service and
Repair) .
8. Install the water pump. Refer to Water Pump Replacement (RPO LNJ) (See: Water
Pump/Service and Repair)Water Pump Replacement (RPO
LY7) (See: Water Pump/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3570
9. Install the right engine mount bracket (1).
10. Install the right engine mount bracket bolts (2-4).
Tighten the bolts to 55 N.m (41 lb ft).
11. Install the engine mount bracket bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
12. Install the left belt idler pulley. Refer to Drive Belt Idler Pulley Replacement - Left Side (See:
Drive Belts, Mounts, Brackets and
Accessories/Idler Pulley/Service and Repair/Drive Belt Idler Pulley Replacement - Left Side) .
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 14. Install the engine
oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair) . 15.
Install the lower belt idler pulley. Refer to Drive Belt Idler Pulley Replacement - Lower (See: Drive
Belts, Mounts, Brackets and
Accessories/Idler Pulley/Service and Repair/Drive Belt Idler Pulley Replacement - Lower) .
16. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft
Pulley/Service and Repair) .
17. Lower the vehicle. 18. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts,
Mounts, Brackets and Accessories/Drive Belt/Service and Repair) . 19. Remove the engine support
fixture. 20. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . 21.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection . 22. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static
Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure.......................................................................................................................................
...............................................384-425 kPa (56-62 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Service Precautions > Technician Safety Information > Page 3577
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3580
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3581
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned
ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition
reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference
pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference
pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the
primary fuel tank module, eliminating the need for a return pipe from the engine. A returnless fuel
system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to
the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative
emissions.
An electric turbine style fuel pump attaches to the primary fuel tank module inside the fuel tank.
The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator,
and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint
that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of
the primary fuel tank module. The primary fuel tank module contains a reverse flow check valve.
The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the
fuel rail in order to prevent long cranking times.
The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel
pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet
pump and the secondary jet pump through a restrictive orifice located on the pump cover. The
primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates
a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through
the fuel transfer pipe, to the primary side of the fuel tank.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
*
Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Component
Tests and General Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 384-425 kPa (56-62 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3582
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 384-425 kPa
(56-62 psi).
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail.
3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan
tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF with
a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the primary fuel pump
module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the primary fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Powertrain Management/Computers and Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine
Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Replacement - Chassis
* Fuel Hose/Pipes Replacement - Engine Compartment
* Fuel Injector Replacement
* Primary Fuel Tank Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Inlet Duct Replacement
Removal Procedure
1. Loosen the clamps at both ends of the air cleaner intake duct. 2. Remove the positive crankcase
ventilation (PCV) fresh air pipe from the air cleaner intake duct. 3. Remove the air cleaner intake
duct from the mass air flow (MAF) sensor and throttle body.
Installation Procedure
1. Install the air cleaner intake duct to the MAF sensor and throttle body. 2. Install the PCV fresh air
pipe to the air cleaner intake duct.
Notice: Refer to Fastener Notice.
3. Tighten the clamps at both ends of the air cleaner intake duct.
Tighten the clamps to 4 N.m (35 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Release the clamps (2) on the side of the air cleaner assembly. 4. Remove the air cleaner
assembly lid (1) by tilting to release the lid from the lower housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3593
5. Remove the air cleaner element (2) from the lower housing (1).
Installation Procedure
1. Install the air cleaner element (2) into the lower housing (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3594
2. Install the air cleaner assembly lid (1) by first engaging the hinge then lower the cover into the
closed position. 3. Fasten the clamps (2) on the side of the air cleaner assembly.
4. Connect the MAF sensor electrical connector. 5. Install the air cleaner intake duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 3600
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 3601
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > Procedures > Page 3602
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
..................................................................1-2-3-4-5-6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
........................4,018 ohm per meter(1,225 ohmper ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications > Page 3609
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Refer to the list below
for items to be inspected.
1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2.
Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following
conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the
wire and the component connected to the wire should be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications > Page 3610
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the injector sight shield.
Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug
boot only. Do not pull on the spark plug wire or the wire could be damaged.
2. Remove the spark plug wires (1) from the left side spark plugs. 3. Remove the spark plug wires
from the retaining clips (2).
4. Remove the spark plug wires (1) from the right side spark plugs. 5. Remove the spark plug wires
from the retaining clips (2). 6. Remove the spark plug wires from the ignition coil/control module. 7.
Remove the spark plug wires from the engine. 8. If you are replacing the spark plug wires, transfer
any of the following components:
* Boot heat shields
* Spark plug wire conduit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Specifications > Page 3611
* Spark plug wire retaining clips
Installation Procedure
1. Install the spark plug wires (1) to the ignition coil/control module. 2. Install the spark plug wires
(1) to the right side spark plugs. 3. Install the spark plug wires to the retaining clips (2).
4. Install the spark plug wires (1) to the left side spark plugs. 5. Install the spark plug wires to the
retaining clips (2). 6. Install the injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 3620
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 3621
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 3622
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250
> Jan > 11 > Campaign - Spark Plug Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250
> Jan > 11 > Campaign - Spark Plug Wire Warranty Extension > Page 3628
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250
> Jan > 11 > Campaign - Spark Plug Wire Warranty Extension > Page 3629
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250
> Jan > 11 > Campaign - Spark Plug Wire Warranty Extension > Page 3630
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 3631
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.........................................................1.52 mm (0.60 in)
Spark Plug Torque
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
Spark Plug Type
............................................................................................................................................
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 3632
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling-Colder plug
- Pre-ignition causing spark plug and/or engine damage-Hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 3633
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal
combustion by-products from fuels with additives.
* Carbon fouled-Dry, fluffy, black carbon or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 3634
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: Observe the following service precautions:
* Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from
a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads.
* Clean the spark plug recess area before removing the spark plug. Failure to do so can result in
engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the
cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.
* Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either
hotter or colder than those specified for the vehicle. Installing spark plugs of another type can
severely damage the engine.
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs (1) from the cylinder head.
Installation Procedure
Notice: It is important to check the gap of all new and reconditioned spark plugs before installation.
Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an
accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor
engine performance and may even damage the engine.
1. Gap the spark plugs to the specifications. Refer to Ignition System Specifications.
Notice: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if
necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can
cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque
specifications carefully. Over or under-tightening can also cause severe damage to engine or spark
plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Spark Plug > Component Information > Technical Service Bulletins > Page 3635
Notice: Refer to Component Fastener Tightening Notice.
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
2. Install the spark plugs to the cylinder head.
Tighten the spark plugs to 15 N.m (11 lb ft).
3. Install the spark plug wires to the spark plugs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading
should be less than
................................................................................................................................................... 689
kPa (100 psi).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3639
Compression Check: Testing and Inspection
Engine Compression Test
A compression pressure test of the engine cylinders determines the condition of the rings, the
valves, and the head gasket.
Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse
block. Refer to Electrical Center Identification Views .
1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the
cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open
position. 6. Measure the engine compression, using the following procedure:
1. Firmly install the compression gauge to the spark plug hole. 2. Have an assistant crank the
engine through at least 4 compression strokes in the testing cylinder. 3. Record the readings on the
gauge at each stroke. 4. Disconnect the gauge. 5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
* The lowest reading should not be less than 70 percent of the highest reading.
* No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements:
* When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
* When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, the piston rings may be the cause.
* If the compression improves considerably with the addition of three squirts of oil, the piston rings
may be the cause.
* When the compression is low on the first stroke and does not build up in the following strokes, the
valves may be the cause.
* The addition of oil does not affect the compression, the valves may be the cause.
* When the compression is low on two adjacent cylinders, or coolant is present in the crankcase,
the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain
Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Bolt .................................................................................................................................
....................................................... 11 N.m (98 lb in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 3643
Water Pump: Service and Repair
Water Pump Replacement (RPO LNJ) (3.4L)
Special Tools
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Drain the cooling system until the coolant is below the level of the water pump. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (
See: Cooling System/Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill)
(See: Cooling System/Service and Repair )Cooling System Draining and Filling (LY7 Static Fill)
(See: Cooling System/Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill)
(See: Cooling System/Service and Repair) .
2. Loosen the water pump pulley bolts (4). 3. Using the J 39914 rotate the drive belt tensioner (8) to
release the tension on the drive belt. 4. Remove the drive belt from the right idler pulley (2). 5.
Carefully release the J 39914 to relieve the drive belt tensioner spring tension. 6. Remove the J
39914 from the drive belt tensioner (8).
7. Remove the water pump pulley bolts (2). 8. Remove the water pump pulley (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 3644
9. Remove the water pump bolts (3).
10. Remove the water pump (1). 11. Remove the water pump gasket (2). 12. Clean the water pump
mating surfaces.
Installation Procedure
1. Install the water pump gasket (2). 2. Install the water pump (1).
Notice: Refer to Fastener Notice .
3. Install the water pump bolts (3).
Tighten the bolts to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 3645
4. Install the water pump pulley (1). Loosely install the pulley bolts (2).
5. Insure the drive belt is properly centered on all the pulleys except the right idler puller (3). 6.
Using the J 39914 rotate the drive belt tensioner away from the drive belt. 7. Install the drive belt to
the right idler pulley (2). 8. Carefully release the J 39914 allowing the drive belt tensioner (8) to
come in contact with the drive belt. 9. Remove the J 39914 from the drive belt tensioner (8).
10. Inspect the drive belt to insure the belt is properly centered on all the pulleys (1-8). 11. Tighten
the water pump pulley bolts.
Tighten the bolts to 25 N.m (18 lb ft).
12. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Cooling System/Service and Repair)Cooling System
Draining and Filling (LNJ GE 47716 Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 Static Fill) (See: Cooling System/Service and Repair)Cooling System
Draining and Filling (LY7 GE 47716 Fill) (See: Cooling System/Service and Repair) .
13. Inspect the cooling system for leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair
Cooling System Air Bleeder Pipe / Hose: Service and Repair
Coolant Air Bleed Pipe Assembly Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Remove the surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement
(LNJ) (See: Coolant Reservoir/Service and Repair
)Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7) (See: Coolant Reservoir/Service and
Repair) .
3. Reposition the coolant air bleed hose clamp (1) at the coolant air bleed hose. 4. Remove the
coolant air bleed pipe from the coolant air bleed hose (2). 5. Remove the coolant air bleed pipe
bolts (3) from the upper intake manifold. 6. Remove the coolant air bleed pipe from the engine.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Cooling System Air Bleeder Pipe / Hose
> Component Information > Service and Repair > Page 3650
1. Install the coolant air bleed pipe to the engine.
Notice: Refer to Fastener Notice .
2. Install the coolant air bleed pipe bolts (3) to the upper intake manifold.
Tighten the bolt to 10 N.m (89 lb in).
3. Install the coolant air bleed hose (2) to the coolant air bleed pipe. 4. Position the coolant air
bleed hose clamp (1) at the coolant air bleed hose. 5. Install the surge tank inlet hose. Refer to
Radiator Surge Tank Inlet Hose/Pipe Replacement (LNJ) (See: Coolant Reservoir/Service and
Repair
)Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7) (See: Coolant Reservoir/Service and
Repair) .
6. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye
Bulletin No.: 05-06-02-002B
Date: January 18, 2008
INFORMATION
Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6
Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn)
1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008
Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine
2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
*EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave
Supercede:
This bulletin is being revised to include additional model years. Please discard Corporate Bulletin
Number 05-06-02-002A (Section 06 - Engine/Propulsion System).
Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause
DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional
(green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R)
system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the
leak detection dye which alters the color of the DEX-COOL(R) coolant.
A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released
that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak
detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any
system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220)
should be used. The new leak detection dye can be used with both conventional and
DEX-COOL(R) coolant.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Cooling System ...................................................................................................................................
................................................ 10.5 quarts (9.9 liters)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 3657
Coolant: Fluid Type Specifications
ENGINE COOLANT
The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is
designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs
first, if you add only DEX-COOL extended life coolant.
A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will:
^ Give freezing protection down to -34°F (-37°C).
^ Give boiling protection up to 265°F (129°C).
^ Protect against rust and corrosion.
^ Help keep the proper engine temperature.
^ Let the warning lights and gages work as they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle.
WHAT TO USE
Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't
damage aluminum parts. If you use this coolant mixture, you don't need to add anything else.
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some
other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant
warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your
engine could get too hot but you would not get the overheat warning. Your engine could catch fire
and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL
coolant.
NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly
damaged. The repair cost would not be covered by your warranty. Too much water in the mixture
can freeze and crack the engine, radiator, heater core and other parts.
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle
could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement
Coolant Line/Hose: Service and Repair Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Release and slide the heater core inlet hose clamp away from the heater inlet pipe connection.
4. Disconnect the heater core inlet hose from the heater inlet pipe.
5. Remove the heater inlet pipe nut (2). 6. Remove the heater inlet pipe (1). 7. Remove the seal (3)
from the heater inlet pipe (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3662
1. Install a new seal (3) to the heater inlet pipe (1). 2. Apply engine coolant to the heater inlet pipe
seal (3).
3. Install the heater outlet pipe (1).
Notice: Refer to Fastener Notice .
4. Install the heater inlet pipe nut (2).
Tighten the nut to 25 N.m (18 lb ft).
5. Connect the heater core inlet hose to the heater inlet pipe. 6. Position the heater core inlet hose
clamp over the heater inlet pipe connection. 7. Fill the cooling system. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
8. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3663
Coolant Line/Hose: Service and Repair Heater Outlet Hose Replacement
Heater Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Remove the heater outlet hose clamps (1). 4. Remove the heater outlet hose (2).
Installation Procedure
1. Apply engine coolant to the heater outlet hose in order to ease installation.
2. Install the heater outlet hose (2). 3. Install the heater outlet hose clamps (1). 4. Fill the cooling
system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3664
Coolant Line/Hose: Service and Repair Heater Outlet Pipe Replacement
Heater Outlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Remove the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
4. Remove the manifold absolute pressure (MAP) sensor bolt (3) and bracket (2). 5. Rotate the
MAP sensor out of the way of the heater outlet pipe. 6. Disconnect the evaporative emissions
(EVAP) pipe from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting
Service
.
7. Disconnect the electrical connector from the EVAP canister purge solenoid. 8. Disconnect the
exhaust gas recirculation (EGR) valve electrical connector.
9. Release and slide the heater outlet hose clamp (1) away from the heater outlet pipe connection.
10. Disconnect the heater outlet hose (2) from the heater outlet pipe.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3665
11. Release and slide the heater core outlet hose clamp away from the heater outlet pipe
connection. 12. Disconnect the heater core outlet hose from the heater outlet pipe.
13. Remove the wire harness retaining clip (1) from the heater pipe bracket. 14. Remove the fuel
pipe retaining clip (2) from the heater pipe bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3666
15. Remove the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
16. Remove the two nuts (3) and bolt (4) securing the heater outlet pipe to the throttle body. 17.
Remove the heater outlet pipe (2) from the engine.
Installation Procedure
1. Install the heater outlet pipe (2) to the engine.
Notice: Refer to Fastener Notice .
2. Install the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
Tighten the nut to 25 N.m (18 lb ft).
3. Install the heater outlet pipe to the throttle body nuts (3) and bolt (4).
Tighten the nuts and bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3667
4. Install the fuel pipe retaining clip (2) to the heater pipe bracket. 5. Install the wire harness
retaining clip (1) to the heater pipe bracket.
6. Connect the heater core outlet hose to the heater outlet pipe. 7. Position the heater core outlet
hose clamp over the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3668
8. Connect the heater outlet hose (2) to the heater outlet pipe. 9. Position the heater outlet hose
clamp (1) over the heater outlet pipe connection.
10. Connect the electrical connector to the EGR valve. 11. Connect the electrical connector to the
EVAP canister purge solenoid. 12. Connect the EVAP pipe to the EVAP canister purge solenoid.
Refer to Plastic Collar Quick Connect Fitting Service .
13. Reposition the MAP sensor. 14. Install the MAP sensor bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
15. Install the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement . 16. Fill the
cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
17. Install the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3669
Coolant Line/Hose: Service and Repair Thermal Bypass Fitting Replacement
Thermal Bypass Fitting Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Release and slide the thermal bypass pipe hose clamp (2) away from the thermal bypass fitting.
4. Remove the thermal bypass hose (1) from the thermal bypass fitting.
5. Release and slide the heater outlet hose clamp (1) away from the thermal bypass fitting. 6.
Remove the heater outlet hose (2) from the thermal bypass fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3670
7. Remove the thermal bypass fitting bolt (2). 8. Remove the thermal bypass fitting (1). 9. Remove
the seal from the thermal bypass fitting.
Installation Procedure
1. Install a new seal to the thermal bypass fitting. 2. Apply engine coolant to the thermal bypass
fitting seal to ease installation.
3. Install the thermal bypass fitting (1).
Notice: Refer to Fastener Notice .
4. Install the thermal bypass fitting bolt (2).
Tighten the bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3671
5. Install the heater outlet hose (2) to the thermal bypass fitting. 6. Position the heater outlet hose
clamp (1) over the thermal bypass fitting.
7. Install the thermal bypass hose (1) to the thermal bypass fitting. 8. Position the thermal bypass
pipe hose clamp (2) over the thermal bypass fitting. 9. Fill the cooling system. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining
and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3672
Coolant Line/Hose: Service and Repair
Heater Inlet Pipe Replacement
Heater Inlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Release and slide the heater core inlet hose clamp away from the heater inlet pipe connection.
4. Disconnect the heater core inlet hose from the heater inlet pipe.
5. Remove the heater inlet pipe nut (2). 6. Remove the heater inlet pipe (1). 7. Remove the seal (3)
from the heater inlet pipe (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3673
Installation Procedure
1. Install a new seal (3) to the heater inlet pipe (1). 2. Apply engine coolant to the heater inlet pipe
seal (3).
3. Install the heater outlet pipe (1).
Notice: Refer to Fastener Notice .
4. Install the heater inlet pipe nut (2).
Tighten the nut to 25 N.m (18 lb ft).
5. Connect the heater core inlet hose to the heater inlet pipe. 6. Position the heater core inlet hose
clamp over the heater inlet pipe connection. 7. Fill the cooling system. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
8. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Heater Outlet Hose Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3674
Heater Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Remove the heater outlet hose clamps (1). 4. Remove the heater outlet hose (2).
Installation Procedure
1. Apply engine coolant to the heater outlet hose in order to ease installation.
2. Install the heater outlet hose (2). 3. Install the heater outlet hose clamps (1). 4. Fill the cooling
system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Heater Outlet Pipe Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3675
Heater Outlet Pipe Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Remove the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
4. Remove the manifold absolute pressure (MAP) sensor bolt (3) and bracket (2). 5. Rotate the
MAP sensor out of the way of the heater outlet pipe. 6. Disconnect the evaporative emissions
(EVAP) pipe from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting
Service
.
7. Disconnect the electrical connector from the EVAP canister purge solenoid. 8. Disconnect the
exhaust gas recirculation (EGR) valve electrical connector.
9. Release and slide the heater outlet hose clamp (1) away from the heater outlet pipe connection.
10. Disconnect the heater outlet hose (2) from the heater outlet pipe.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3676
11. Release and slide the heater core outlet hose clamp away from the heater outlet pipe
connection. 12. Disconnect the heater core outlet hose from the heater outlet pipe.
13. Remove the wire harness retaining clip (1) from the heater pipe bracket. 14. Remove the fuel
pipe retaining clip (2) from the heater pipe bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3677
15. Remove the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
16. Remove the two nuts (3) and bolt (4) securing the heater outlet pipe to the throttle body. 17.
Remove the heater outlet pipe (2) from the engine.
Installation Procedure
1. Install the heater outlet pipe (2) to the engine.
Notice: Refer to Fastener Notice .
2. Install the heater outlet pipe nut (1) securing the heater outlet pipe (2) to the intake manifold.
Tighten the nut to 25 N.m (18 lb ft).
3. Install the heater outlet pipe to the throttle body nuts (3) and bolt (4).
Tighten the nuts and bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3678
4. Install the fuel pipe retaining clip (2) to the heater pipe bracket. 5. Install the wire harness
retaining clip (1) to the heater pipe bracket.
6. Connect the heater core outlet hose to the heater outlet pipe. 7. Position the heater core outlet
hose clamp over the heater outlet pipe connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3679
8. Connect the heater outlet hose (2) to the heater outlet pipe. 9. Position the heater outlet hose
clamp (1) over the heater outlet pipe connection.
10. Connect the electrical connector to the EGR valve. 11. Connect the electrical connector to the
EVAP canister purge solenoid. 12. Connect the EVAP pipe to the EVAP canister purge solenoid.
Refer to Plastic Collar Quick Connect Fitting Service .
13. Reposition the MAP sensor. 14. Install the MAP sensor bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
15. Install the air cleaner air intake duct. Refer to Air Cleaner Inlet Duct Replacement . 16. Fill the
cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
17. Install the injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Fitting Replacement
Thermal Bypass Fitting Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3680
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
3. Release and slide the thermal bypass pipe hose clamp (2) away from the thermal bypass fitting.
4. Remove the thermal bypass hose (1) from the thermal bypass fitting.
5. Release and slide the heater outlet hose clamp (1) away from the thermal bypass fitting. 6.
Remove the heater outlet hose (2) from the thermal bypass fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3681
7. Remove the thermal bypass fitting bolt (2). 8. Remove the thermal bypass fitting (1). 9. Remove
the seal from the thermal bypass fitting.
Installation Procedure
1. Install a new seal to the thermal bypass fitting. 2. Apply engine coolant to the thermal bypass
fitting seal to ease installation.
3. Install the thermal bypass fitting (1).
Notice: Refer to Fastener Notice .
4. Install the thermal bypass fitting bolt (2).
Tighten the bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3682
5. Install the heater outlet hose (2) to the thermal bypass fitting. 6. Position the heater outlet hose
clamp (1) over the thermal bypass fitting.
7. Install the thermal bypass hose (1) to the thermal bypass fitting. 8. Position the thermal bypass
pipe hose clamp (2) over the thermal bypass fitting. 9. Fill the cooling system. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining
and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Hose Replacement
Thermal Bypass Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3683
3. Release and slide the thermal bypass pipe hose clamps (2) away from the hose connections. 4.
Remove thermal bypass hose (1).
Installation Procedure
1. Apply engine coolant to the bypass hose in order to ease installation.
2. Install the thermal bypass pipe hose (1). 3. Position the thermal bypass pipe hose clamps (2)
over the hose end connections. 4. Fill the cooling system. Refer to Cooling System Draining and
Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
Thermal Bypass Pipe Replacement
Thermal Bypass Pipe Replacement
Tools Required
J 21882 Oil Suction Pipe Installer
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component
Information > Service and Repair > Heater Inlet Pipe Replacement > Page 3684
2. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement (See:
Engine/Intake Manifold/Service and Repair) . 3. Remove the thermal bypass hose. Refer to
Thermal Bypass Hose Replacement (See: ) .
4. Remove the thermal bypass pipe bolt. 5. Remove the thermal bypass pipe .
Installation Procedure
1. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the end of the
thermal bypass pipe where the pipe is pressed into the
intake manifold.
2. Install the thermal bypass pipe using J 21882 .
Notice: Refer to Fastener Notice .
3. Install the thermal bypass pipe bolt.
Tighten the bolt to 10 N.m (89 lb in).
4. Install the thermal bypass hose. Refer to Thermal Bypass Hose Replacement (See: ) . 5. Install
the upper intake manifold. Refer to Upper Intake Manifold Replacement (See: Engine/Intake
Manifold/Service and Repair) . 6. Fill the engine with coolant. Refer to Cooling System Draining
and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining
and Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair )Cooling System Draining and Filling (LY7 GE 47716 Fill)
(See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Inlet Hose/Pipe Replacement
Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement
Radiator Surge Tank Inlet Hose/Pipe Replacement (LNJ) (3.4L)
Removal Procedure
1. Remove the surge tank inlet hose clamp from the surge tank. 2. Remove the surge tank inlet
hose from the surge tank.
3. Remove the surge tank inlet hose clamp from the engine. 4. Remove the surge tank inlet hose
from the engine.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Inlet Hose/Pipe Replacement > Page 3689
1. Install the surge tank inlet hose to the engine. 2. Install the surge tank inlet hose clamp to the
engine.
3. Install the surge tank inlet hose to the surge tank. 4. Install the surge tank inlet hose clamp to the
surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Inlet Hose/Pipe Replacement > Page 3690
Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement
Radiator Surge Tank Replacement
Tools Required
GE-47716 Vac N Fill Coolant Refill Tool
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
2. Remove the surge tank inlet hose clamp from the surge tank. 3. Disconnect the surge tank inlet
hose from the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Inlet Hose/Pipe Replacement > Page 3691
4. Remove the surge tank bolts from the surge tank. 5. Lift the surge tank to gain access to the
heater outlet hose. 6. Remove the heater outlet hose clamp from the surge tank. 7. Remove the
heater outlet hose from the surge tank. 8. Remove the surge tank from the vehicle.
Installation Procedure
1. Install the heater outlet hose to the surge tank. 2. Install the surge tank to the vehicle.
Notice: Refer to Fastener Notice .
3. Install the surge tank bolts to the surge tank.
Tighten the bolts to 9 N.m (80 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component
Information > Service and Repair > Radiator Surge Tank Inlet Hose/Pipe Replacement > Page 3692
4. Connect the surge tank inlet hose to the surge tank. 5. Install the surge tank inlet hose clamp to
the surge tank. 6. Fill the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static
Fill) (See: Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Service and Repair
Radiator Cooling Fan Motor: Service and Repair
Engine Coolant Fan Motor Replacement
Tools Required
GE-47827 Socket
This vehicle is equipped with counter-rotating engine cooling fans. The right hand fan will require
the use of GE-47827 or equivalent for fan blade removal. The left hand fan blade can be removed
using a normal six point socket.
Removal Procedure
Caution: An electric fan under the hood can start up even when the engine is not running and can
injure you. Keep hands, clothing and tools away from any underhood electric fan.
Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan
blade or housing should always be replaced.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment
come in contact with an exposed electrical terminal. Failure to follow these precautions may result
in personal injury and/or damage to the vehicle or its components.
1. Remove the fan shroud assembly from the vehicle. Refer to Cooling Fan and Shroud
Replacement (See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Service and Repair > Page 3697
Important: Hold the fan blade to prevent rotation.
2. Using GE-47827 or equivalent , turn the fan motor drive plate in the opposite direction of the
arrow stamped on the fan blade. 3. Remove and discard the fan blade.
Notice: Prior to center punching and drilling out rivets, support the fan motor and shroud by placing
a block of wood or other solid object under the fan motor. Failure to support the fan motor while
drilling may result in a cracked fan shroud.
Notice: Failure to tape off all of the entry points to the cooling fan motor(s) will allow debris to enter
and damage the motor(s).
Important: When reusing the fan motor(s) tape off the front and rear entry points of the fan motor(s)
before drilling the rivets. Support the fan motor(s) and shroud prior to center punching the rivets.
4. Center punch each of the rivets (1) from the rear of the motor. 5. Drill the head of the rivets (1)
from the fan motor using a 6.35 mm (0.25 in) drill bit.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Service and Repair > Page 3698
6. Tap the rivets out of the fan shroud.
7. Remove the fan motor from the fan shroud.
Important: Blow off any excess debris from the fan motor.
8. Remove the tape covering the entry points from the fan motor.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Service and Repair > Page 3699
1. Install the engine cooling fan motor to the fan shroud.
Important: Position the fan motor to the fan shroud and insert the bolts from the front side.
2. Install the cooling fan motor bolts.
Notice: Refer to Fastener Notice .
3. Install the cooling fan motor nuts.
Tighten the nuts to 6 N.m (53 lb in).
Notice: Failure to heat the fan hub in hot tap water before installation will result in cooling fan failure
due to cracking. Allowing the heated fan to cool for more than one minute prior to installation will
also result in failure due to cracking.
Important: Using hot tap water at a minimum of 49°C (120°F), hold the new fan blade hub under
the running water for a minimum of 60 seconds to heat the fan blade to the temperature of the
water.
Immediately after heating, position the fan blade on the fan motor drive plate.
4. Install the new engine cooling fan blade. 5. Using the GE-47827 , or equivalent turn the fan
motor drive plate in the same direction of the arrow on the fan blade until the fan motor drive
plate engages to the fan blade.
6. Rotate the cooling fan blade to ensure proper rotation. 7. Install the fan shroud assembly to the
vehicle. Refer to Cooling Fan and Shroud Replacement (See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3707
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3708
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3709
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3710
Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators
Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators
INFORMATION
Bulletin No.: 05-06-02-001A
Date: July 16, 2008
Subject: Information On Aluminum Heater Core and/or Radiator Replacement
Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005
HUMMER H2
Supercede:
This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin
Number 05-06-02-001 (Section 06 - Engine/Propulsion System).
Important:
2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the
flushing procedure explained later in this bulletin.
The following information should be utilized when servicing aluminum heater core and/or radiators
on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient
inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check
should be performed whenever a heater core, radiator, or water pump is replaced. The following
procedures/ inspections should be done to verify proper coolant effectiveness.
Caution:
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge
tank cap is removed while the engine and radiator are still hot.
Important:
If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water
to the system, then the system should be completely flushed using the procedure explained later in
this bulletin.
Technician Diagnosis
^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion
protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the
measurement of coolant concentration. This must be done by using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer
uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or
the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the
coolant concentration fully and should not be used. The concentration levels should be between
50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees
Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be
flushed.
^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information
(SI) and/or the appropriate Service Manual for component location and condition for operation.
^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed
before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test
lead to the negative battery post and insert the other test lead into the radiator coolant, making sure
the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that
stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that
occurs when a device or accessory that is mounted to the radiator is energized. This type of current
could be caused from a poorly grounded cooling fan or some other accessory and can be verified
by watching the volt meter and turning on and off various accessories or engage the starter motor.
Before using one of the following flush procedures, the coolant recovery reservoir must be
removed, drained, cleaned and reinstalled before refilling the system.
Notice:
^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle.
^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The
repair cost would not be covered by your warranty. Too much water in the mixture can freeze and
crack the engine, radiator, heater core and other parts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3715
Flushing Procedures using DEX-COOL(R)
Important:
The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in
Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a
service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior
to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the
Owner's Manual.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of
properly following the draining procedures in the appropriate Service Manual. Refill the system
using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the
vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear.
Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with
DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R),
P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear,
drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached
the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add
clean water to restore the coolant to the appropriate level.
Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration
levels should be between 50% and 65%.
Flushing Procedures using Conventional Silicated (Green Colored) Coolant
Important:
2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R).
The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color.
Silicated coolants are typically green in color and are required to be drained, flushed and refilled
every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated
coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's
Manual or Service Information (SI) for further information on OEM coolant.
Important:
Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when
adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and
green colored coolants will produce a brown coolant which may be a customer dissatisfier and will
not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by
GM Service and Parts Operations are green in color.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of
properly following the draining procedures in appropriate Service Manual. Refill the system using
clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3)
times to totally remove old coolant or until drained coolant is almost clear. Once the system is
completely flushed, refill the cooling system to a 50%-60% concentration with a good quality
ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L),
conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% good quality
ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N
88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water
(preferably distilled) to system until the level of the coolant mixture has reached the base of the
radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to
restore coolant to the appropriate level.
Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels
should be between 50% and 65%.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3716
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3717
Heater Core: Service and Repair
Heater Core Replacement
Removal Procedure
1. Remove the HVAC module from the vehicle.
2. Remove the heater core cover screws from the HVAC module.
3. Remove the heater core cover from the HVAC module.
4. Remove the heater core from the HVAC module.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3718
1. Install the heater core to the HVAC module.
2. Install the heater core cover to the HVAC module.
Notice: Refer to Fastener Notice.
3. Install the heater core cover screws to the HVAC module.
Tighten the screw to 1.5 N.m (13 lb in).
4. Install the HVAC module to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ)
Heater Hose: Service and Repair Heater Inlet Hose Replacement (LNJ)
Heater Inlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater inlet hose clamp from the heater core. 3. Remove the heater inlet hose (2)
from the heater core.
4. Remove the heater inlet hose clamp from the engine. 5. Remove the heater inlet hose (2) from
the engine. 6. Remove the heater inlet hose (2) from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ) > Page 3723
Installation Procedure
1. Install the heater inlet hose (2) to the vehicle. 2. Install the heater inlet hose (2) to the engine. 3.
Install the heater inlet hose clamp to the engine.
4. Install the heater inlet hose (2) to the heater core. 5. Install the heater inlet hose clamp to the
heater core. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ) > Page 3724
Heater Hose: Service and Repair Heater Outlet Hose Replacement (LNJ)
Heater Outlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater outlet hose clamp from the heater core. 3. Remove the heater outlet hose (1)
from the heater core.
4. Remove the heater outlet hose clamp from the engine. 5. Remove the heater outlet hose (1)
from the engine. 6. Position the loose end of the heater outlet hose (1) outboard to ease in the
removal of the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ) > Page 3725
7. Remove the surge tank inlet hose clamp from the surge tank. 8. Disconnect the surge tank inlet
hose from the surge tank.
9. Remove the surge tank bolts from the surge tank.
10. Lift the surge tank to gain access to the heater outlet hose. 11. Remove the heater outlet hose
clamp from the surge tank. 12. Remove the heater outlet hose from the surge tank. 13. Remove
the surge tank from the vehicle. 14. Remove the heater outlet hose clamp from the hose. This will
aid in routing the heater outlet hose from the vehicle. 15. Remove the heater outlet hose from the
vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ) > Page 3726
1. Install the heater outlet hose to the vehicle. Route the hose into position for attachment to the
surge tank. 2. Install the heater outlet hose clamp to the hose. 3. Install the heater outlet hose to
the surge tank. 4. Install the surge tank to the vehicle.
Notice: Refer to Fastener Notice.
5. Install the surge tank bolts to the surge tank.
Tighten the bolts to 8 N.m (71 lb in).
6. Connect the surge tank inlet hose to the surge tank. 7. Install the surge tank inlet hose clamp to
the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Inlet Hose Replacement (LNJ) > Page 3727
8. Install the heater outlet hose (1) to the engine. 9. Install the heater outlet hose clamp to the
engine.
10. Install the heater outlet hose (1) to the heater core. 11. Install the heater outlet hose clamp to
the heater core. 12. Fill the engine coolant. Refer to Cooling System Draining and Filling (LNJ
Static Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Component Information > Service and Repair
Radiator Drain Plug: Service and Repair
Radiator Drain Cock Replacement
Tools Required
GE-47716 Vac N Fill Coolant Refill Tool
Removal Procedure
1. Drain the radiator. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 Static Fill)
(See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See: Service
and Repair) .
2. Unscrew the drain plug from the radiator end tank. 3. Remove and discard the O-ring.
Installation Procedure
1. Install the new O-ring.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Component Information > Service and Repair > Page 3732
2. Install and tighten the drain plug into the end tank drain hole. 3. Fill the radiator. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System Draining
and Filling
(LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 Static Fill)
(See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See: Service
and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Service Precautions
Radiator Cap: Service Precautions
Radiator Cap Removal Caution
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine
is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or
surge tank cap is removed while the engine and radiator are still hot.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Service Precautions > Page 3736
Radiator Cap: Testing and Inspection
Pressure Cap Testing
Tools Required
* J 24460-01 Cooling System Pressure Tester
* J 42401 Radiator Cap/Surge Tank Test Adapter
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine
is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or
surge tank cap is removed while the engine and radiator are still hot.
1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure
cap for the following conditions:
* Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap.
* Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions:
* The pressure cap does not release pressure which exceeds the rated pressure of the cap.
* The pressure cap does not hold the rated pressure.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement
Radiator Hose: Service and Repair Radiator Inlet Hose Replacement
Radiator Inlet Hose Replacement (LNJ 3.4L Chevrolet)
Removal Procedure
1. Drain the coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 Static Fill)
(See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See: Service
and Repair) .
2. Remove the upper fascia retainers from the radiator support. 3. Remove the upper radiator
bracket bolt from the radiator support. 4. Remove the upper radiator bracket from the radiator. 5.
Remove the radiator inlet hose clamp from the radiator.
6. Remove the radiator inlet hose from the radiator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 3741
7. Remove the radiator inlet hose clamp from the engine. 8. Remove the radiator inlet hose from
the engine.
Installation Procedure
1. Install the radiator inlet hose to the engine. 2. Install the radiator inlet hose clamp to the engine.
3. Install the radiator inlet hose to the radiator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 3742
4. Install the radiator inlet hose clamp to the radiator. 5. Install the upper radiator bracket to the
radiator.
Notice: Refer to Fastener Notice .
6. Install the upper radiator bracket bolt to the radiator support.
Tighten the bolt to 20 N.m (15 lb ft).
7. Install the upper fascia retainers to the radiator support. 8. Fill the cooling system. Refer to
Cooling System Draining and Filling (LNJ Static Fill) (See: Service and Repair)Cooling System
Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 3743
Radiator Hose: Service and Repair Radiator Outlet Hose Replacement
Radiator Outlet Hose Replacement (LNJ) (3.4L)
Removal Procedure
1. Drain the coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See: Service
and Repair)Cooling System Draining and Filling
(LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 Static Fill)
(See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See: Service
and Repair) .
2. Remove the radiator outlet hose clamp from the engine. 3. Remove the radiator outlet hose from
the engine.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 5. Remove the radiator
outlet hose clamp from the radiator. 6. Remove the radiator outlet hose from the radiator.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information
> Service and Repair > Radiator Inlet Hose Replacement > Page 3744
1. Install the radiator outlet hose to the radiator. 2. Install the radiator outlet hose clamp to the
radiator. 3. Lower the vehicle.
4. Install the radiator outlet hose to the engine. 5. Install the radiator outlet hose clamp to the
engine. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill)
(See: Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3754
Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3755
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3756
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System
> Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3757
Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications
Thermostat: Specifications
Thermostat Full Open Temperature ....................................................................................................
............................................................. 91° C 195° F
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications > Page 3761
Thermostat: Service and Repair
Engine Coolant Thermostat Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the coolant until the coolant level is below the thermostat. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling
System Draining and Filling (LY7 Static Fill) (See: Service and Repair)Cooling System Draining
and Filling (LY7 GE 47716 Fill) (See: Service and Repair) .
3. Remove the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LNJ) (See:
Exhaust System/Exhaust Pipe/Service and Repair)
.
4. Remove the radiator hose from the thermostat housing. Refer to Radiator Inlet Hose
Replacement (LNJ Chevrolet) (See: Radiator Hose/Service
and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LY7).
5. Remove the thermostat housing bolts (3) and clean any sealer from the bolt threads. 6. Remove
the thermostat housing (1). 7. Remove the thermostat (2). 8. Clean the mating surfaces.
Installation Procedure
1. Install the thermostat (2). 2. Install the thermostat housing (1). 3. Install RTV sealer, GM P/N
12378478 (Canadian P/N 88900041) or the equivalent, to the thermostat housing bolt threads.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling >
Component Information > Specifications > Page 3762
4. Install the thermostat housing bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the radiator hose to the thermostat housing. Refer to Radiator Inlet Hose Replacement
(LNJ Chevrolet) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LY7).
6. Install the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LNJ) (See:
Exhaust System/Exhaust Pipe/Service and Repair) . 7. Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
8. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
9. Inspect the cooling system for leaks. Repair as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Engine Coolant Thermostat Housing Replacement
Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement
Engine Coolant Thermostat Housing Replacement (RPO LNJ) (3.4L)
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See:
Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
2. Drain the coolant until the coolant level is below the thermostat. Refer to Cooling System
Draining and Filling (LNJ Static Fill) (See: Service and
Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling
System Draining and Filling (LY7 Static Fill) (See: Service and Repair)Cooling System Draining
and Filling (LY7 GE 47716 Fill) (See: Service and Repair) .
3. Remove the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LNJ) (See:
Exhaust System/Exhaust Pipe/Service and Repair)
.
4. Remove the radiator hose from the thermostat housing. Refer to Radiator Inlet Hose
Replacement (LNJ Chevrolet) (See: Radiator Hose/Service
and Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LY7).
5. Remove the thermostat housing bolts (3) and clean any sealer from the bolt threads. 6. Remove
the thermostat housing (1). 7. Remove the thermostat (2). 8. Clean the mating surfaces.
Installation Procedure
1. Install the thermostat (2). 2. Install the thermostat housing (1). 3. Install RTV sealer, GM P/N
12378478 (Canadian P/N 88900041) or the equivalent, to the thermostat housing bolt threads.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Engine Coolant Thermostat Housing Replacement > Page 3767
Notice: Refer to Fastener Notice .
4. Install the thermostat housing bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the radiator hose to the thermostat housing. Refer to Radiator Inlet Hose Replacement
(LNJ Chevrolet) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LNJ Pontiac) (See: Radiator Hose/Service and
Repair)Radiator Inlet Hose Replacement (LY7).
6. Install the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LNJ) (See:
Exhaust System/Exhaust Pipe/Service and Repair) . 7. Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement (See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Sight Shield
Replacement) .
8. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
9. Inspect the cooling system for leaks. Repair as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Engine Coolant Thermostat Housing Replacement > Page 3768
Thermostat Housing: Service and Repair Water Outlet Housing Replacement
Water Outlet Housing Replacement
Removal Procedure
1. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LNJ) (See:
Radiator Hose/Service and Repair)Radiator Outlet Hose
Replacement (LY7) (See: Radiator Hose/Service and Repair) .
2. Remove the water outlet housing bolts (1). 3. Remove the housing. 4. Remove the water outlet
housing O-ring seal (2). 5. Remove the water outlet housing seal (3). Discard seal.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Engine Coolant Thermostat Housing Replacement > Page 3769
1. Install a NEW water outlet housing seal (3). 2. Install a NEW water outlet housing O-ring seal (2).
Notice: Refer to Fastener Notice .
3. Install the water outlet housing bolts (1).
Tighten the water outlet housing bolts to 10 N.m (89 lb in).
4. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LNJ) (See: Radiator
Hose/Service and Repair)Radiator Outlet Hose
Replacement (LY7) (See: Radiator Hose/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Bolt .................................................................................................................................
....................................................... 11 N.m (98 lb in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3773
Water Pump: Service and Repair
Water Pump Replacement (RPO LNJ) (3.4L)
Special Tools
J 39914 Serpentine Belt Tensioner Unloader
Removal Procedure
1. Drain the cooling system until the coolant is below the level of the water pump. Refer to Cooling
System Draining and Filling (LNJ Static Fill) (
See: Service and Repair)Cooling System Draining and Filling (LNJ GE 47716 Fill) (See: Service
and Repair)Cooling System Draining and Filling (LY7 Static Fill) (See: Service and Repair)Cooling
System Draining and Filling (LY7 GE 47716 Fill) (See: Service and Repair) .
2. Loosen the water pump pulley bolts (4). 3. Using the J 39914 rotate the drive belt tensioner (8) to
release the tension on the drive belt. 4. Remove the drive belt from the right idler pulley (2). 5.
Carefully release the J 39914 to relieve the drive belt tensioner spring tension. 6. Remove the J
39914 from the drive belt tensioner (8).
7. Remove the water pump pulley bolts (2). 8. Remove the water pump pulley (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3774
9. Remove the water pump bolts (3).
10. Remove the water pump (1). 11. Remove the water pump gasket (2). 12. Clean the water pump
mating surfaces.
Installation Procedure
1. Install the water pump gasket (2). 2. Install the water pump (1).
Notice: Refer to Fastener Notice .
3. Install the water pump bolts (3).
Tighten the bolts to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3775
4. Install the water pump pulley (1). Loosely install the pulley bolts (2).
5. Insure the drive belt is properly centered on all the pulleys except the right idler puller (3). 6.
Using the J 39914 rotate the drive belt tensioner away from the drive belt. 7. Install the drive belt to
the right idler pulley (2). 8. Carefully release the J 39914 allowing the drive belt tensioner (8) to
come in contact with the drive belt. 9. Remove the J 39914 from the drive belt tensioner (8).
10. Inspect the drive belt to insure the belt is properly centered on all the pulleys (1-8). 11. Tighten
the water pump pulley bolts.
Tighten the bolts to 25 N.m (18 lb ft).
12. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) (See:
Service and Repair)Cooling System Draining and
Filling (LNJ GE 47716 Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7
Static Fill) (See: Service and Repair)Cooling System Draining and Filling (LY7 GE 47716 Fill) (See:
Service and Repair) .
13. Inspect the cooling system for leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure
1. Remove the muffler assembly. Refer to Muffler Replacement (LNJ) (See: Muffler/Service and
Repair)Muffler Replacement (LY7) (See:
Muffler/Service and Repair) .
2. If the vehicle is equipped with all wheel drive (AWD) remove the propeller shaft underbody guard
loop bolts and guard loop.
Important: Support the fuel tank prior to removing the fuel tank strap bolt.
3. Remove the right fuel tank strap bolt, which also secures the rear of the catalytic converter heat
shield to the underbody.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair > Page 3781
Important: The heat shields at the dash panel and the catalytic converter overlap and utilizing
common rivet attachment points.
4. Drill out the rivets. 5. Remove the catalytic converter heat shield.
Installation Procedure
1. Position the catalytic converter heat shield, and insert the catalytic converter heat shield between
the underbody and the dash panel heat shield. 2. Install the NEW rivets.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield >
Component Information > Service and Repair > Page 3782
Notice: Refer to Fastener Notice .
3. Install the fuel tank strap bolt.
Tighten the bolt to 25 N.m (18 lb ft).
4. If the vehicle is equipped with AWD, install the propeller shaft underbody guard loop and bolts.
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the muffler assembly. Refer to Muffler Replacement (LNJ) (See: Muffler/Service and
Repair)Muffler Replacement (LY7) (See:
Muffler/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Nut ..........................................................................................................................
....................................................... 16 N.m (12 lb ft) Exhaust Manifold Stud ......................................
.......................................................................................................................................... 18 N.m (13
lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side
Exhaust Manifold Replacement - Left Side (LNJ) (3.4L)
Removal Procedure
1. Remove the 3 nuts attaching the exhaust crossover pipe to the left exhaust manifold. Refer to
Exhaust Crossover Pipe Replacement (LNJ) (See:
Exhaust Pipe/Service and Repair) .
2. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe
Replacement .
3. Remove the exhaust manifold heat shield bolts (2). 4. Remove the exhaust manifold heat shield
(1).
5. Remove the exhaust manifold nuts (3). 6. Remove the exhaust manifold (2). 7. Remove the
exhaust manifold gasket (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3788
8. If necessary, remove the exhaust manifold studs. 9. Clean the exhaust manifold and the cylinder
head exhaust manifold sealing surfaces.
Installation Procedure
Notice: Refer to Fastener Notice .
1. If previously removed, install the exhaust manifold studs.
Tighten the studs to 18 N.m (13 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3789
2. Install the exhaust manifold gasket (1). 3. Install the exhaust manifold (2). 4. Install the exhaust
manifold nuts (3).
Tighten the nuts to 16 N.m (12 lb ft).
5. Install the exhaust manifold heat shield (1). 6. Install the exhaust manifold heat shield bolts (2).
Tighten the bolts to 10 N.m (89 lb in).
7. Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement . 8. Install the 3 nuts
attaching the exhaust crossover pipe to the left exhaust manifold. Refer to Exhaust Crossover Pipe
Replacement (LNJ) (See:
Exhaust Pipe/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3790
Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side
Exhaust Manifold Replacement - Right Side (LNJ) (3.4L)
Removal Procedure
1. Disconnect the oxygen sensor electrical connector. 2. Remove the 3 nuts attaching exhaust
crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement (LNJ)
(See:
Exhaust Pipe/Service and Repair) .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the nuts (3) securing the catalytic converter (4) to the exhaust manifold and position
catalytic converter out of the way. Refer to Catalytic
Converter Replacement (LNJ) (See: Catalytic Converter/Service and Repair) .
5. Remove the exhaust manifold heat shield bolts (3). 6. Remove the exhaust manifold heat shields
(1, 2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3791
7. Remove the exhaust manifold nuts (3). 8. Remove the exhaust manifold (2). 9. Remove the
exhaust manifold gasket (1).
10. If you are REPLACING the engine right side exhaust manifold, remove the heated oxygen
sensor (HO2S). Refer to Heated Oxygen Sensor 1
Replacement .
11. If necessary, remove the exhaust manifold studs. 12. Clean the exhaust manifold and the
cylinder head exhaust manifold sealing surfaces.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3792
Notice: Refer to Fastener Notice .
1. If previously removed, install the exhaust manifold studs.
Tighten the studs to 18 N.m (13 lb ft).
2. If removed, install the HO2S. Refer to Heated Oxygen Sensor 1 Replacement .
3. Install the exhaust manifold gasket (1). 4. Install the exhaust manifold (2). 5. Install the exhaust
manifold nuts (3).
Tighten the nuts to 16 N.m (12 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Service and Repair > Exhaust Manifold Replacement - Left Side > Page 3793
6. Install the exhaust manifold upper heat shield (1). 7. Install the exhaust manifold lower heat
shield (2). 8. Install the exhaust manifold heat shield bolts (3).
Tighten the bolts to 10 N.m (89 lb in).
9. Install the catalytic converter (4) to the exhaust manifold and install the nuts (3). Refer to
Catalytic Converter Replacement (LNJ) (See: Catalytic
Converter/Service and Repair) .
10. Lower the vehicle. 11. Install the exhaust crossover pipe nuts to the right side exhaust manifold.
Refer to Exhaust Crossover Pipe Replacement (LNJ) (See: Exhaust
Pipe/Service and Repair) .
12. Connect the HO2S electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information
> Service and Repair
Exhaust Pipe: Service and Repair
Exhaust Crossover Pipe Replacement (LNJ) (3.4L)
Removal Procedure
1. Remove the battery box. Refer to Battery Box Replacement .
2. Remove the exhaust crossover pipe nuts (2). 3. Remove the exhaust crossover pipe (3). 4.
Remove the exhaust manifold studs (1), if replacement of the stud is necessary.
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install any previously removed exhaust manifold studs (1).
Tighten the studs to 25 N.m (18 lb ft).
2. Install the exhaust crossover pipe (3).
Important: Maintain approximately 6.35 mm (0.25 in) between the thermostat housing and the
exhaust crossover pipe.
3. Install the exhaust crossover pipe nuts (2).
Tighten the nuts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information
> Service and Repair > Page 3797
4. Install the battery box. Refer to Battery Box Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Fuel Tank Heat Shield Replacement
Heat Shield: Service and Repair Fuel Tank Heat Shield Replacement
Fuel Tank Heat Shield Replacement
Removal Procedure
1. Remove the fuel tank. Refer to one of the following:
* Fuel Tank Replacement (AWD) Fuel Tank Replacement (FWD) for the 3.4L
* Fuel Tank Replacement (AWD) Fuel Tank Replacement (FWD) for the 3.6L
2. Cut the strap around the fuel tank, if required. 3. Remove the fuel tank shield from the fuel tank.
* Fuel Tank Replacement (AWD) Fuel Tank Replacement (FWD) for the 3.4L
* Fuel Tank Replacement (AWD) Fuel Tank Replacement (FWD) for the 3.6L
Installation Procedure
1. Install the fuel tank shield to the fuel tank. 2. Install the fuel tank. Refer to one of the following:
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Fuel Tank Heat Shield Replacement > Page 3802
Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side
Exhaust Manifold Heat Shield Replacement - Right Side (LNJ) (3.4L)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the
heat shield bolts (3). 3. Remove the lower heat shield (2) from the exhaust manifold. 4. Remove the
upper heat shield (1) from the exhaust manifold.
Installation Procedure
1. Install the upper heat shield (1) to the exhaust manifold. 2. Install the lower heat shield (2) to the
exhaust manifold.
Notice: Refer to Fastener Notice .
3. Install the heat shield bolts to the exhaust manifold.
Tighten the bolts to 10 N.m (89 lb in).
4. Lower the vehicle.
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Fuel Tank Heat Shield Replacement > Page 3803
Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side
Exhaust Manifold Heat Shield Replacement - Left Side (LNJ) (3.4L)
Removal Procedure
1. Remove the heat shield bolts (2). 2. Remove the heat shield (1) from the exhaust manifold.
Installation Procedure
1. Install the heat shield (1) to the exhaust manifold.
Notice: Refer to Fastener Notice .
2. Install the heat shield bolts (2) to the exhaust manifold.
Tighten the bolts to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Fuel Tank Heat Shield Replacement > Page 3804
Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel
Exhaust Heat Shield Replacement - Dash Panel
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the dash
panel heat shield nut.
Important: The heat shields at the dash panel and the catalytic converter overlap and utilizing
common rivet attachment points.
3. Drill out the dash panel heat shield rivets. 4. Remove the dash panel heat shield.
Installation Procedure
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair > Fuel Tank Heat Shield Replacement > Page 3805
1. Position the dash panel heat shield to the underbody, installing the shield over the stud.
Notice: Refer to Fastener Notice .
2. Install the dash panel heat shield nut.
Tighten the nut to 10 N.m (89 lb in).
3. Install NEW rivets. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair
Muffler: Service and Repair
Muffler Replacement (LNJ) (3.4L)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the catalytic
converter pipe flange to muffler pipe flange nuts.
3. With the aid of an assistant, separate the rubber insulators (5, 6, and 7) from the exhaust pipe
hangers (1, 2, and 3).
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Page 3809
4. With the aid of an assistant, remove the muffler assembly (3) from catalytic converter (1) and the
vehicle.
Installation Procedure
1. With the aid of an assistant, install the muffler assembly (3) to catalytic converter (1) and the
vehicle.
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Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Service and Repair > Page 3810
2. With the aid of an assistant, install the rubber insulators (5, 6, and 7) to the exhaust pipe hangers
(1, 2, and 3).
3. Install a NEW catalytic converter to muffler gasket onto the studs.
Notice: Refer to Fastener Notice .
4. Install the catalytic converter pipe flange to muffler pipe flange nuts.
Tighten the nuts to 37 N.m (27 lb ft).
5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
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> Body Controls - Unable To Reprogram Body Control Module > Page 3818
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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> Body Controls - Unable To Reprogram Body Control Module > Page 3819
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Body Controls - Unable To Reprogram Body Control Module > Page 3820
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3821
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Lower Center Instrument Panel Components
1 - Body Control Module (BCM) 2 - Instrument Panel Harness 3 - Center Instrument Panel Support
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3822
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3823
Body Control Module (BCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3824
Body Control Module (BCM) X3
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3825
Body Control Module (BCM) X4
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Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3826
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3827
Body Control Module (BCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3828
Body Control Module (BCM) X6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3829
Body Control Module (BCM) X7
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> Page 3830
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Page 3831
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important: If data is not retrieved from the malfunctioning body control module (BCM), additional
time will be required to program the replacement BCM.
1. Retrieve data from the malfunctioning BCM. 2. Rotate the ignition switch to the OFF position.
3. Remove the radio bezel. 4. Disconnect the BCM electrical harnesses. 5. Remove the BCM from
the instrument panel (I/P) retainer:
1. Pry the BCM tabs from the locking tabs on the underside of the restraint. 2. Slide the BCM out of
the retainer.
Installation Procedure
1. Install the BCM. 2. Install the radio bezel. 3. Slide the BCM tabs into the slots in the I/P retainer
until the tabs lock into place. 4. Connect the electrical connectors. 5. Program a new or a
remanufactured BCM.
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Electronic Throttle Control Module: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Page 3835
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 1 of 2 (LNJ)
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Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 3836
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 3837
Electronic Throttle Control Module: Diagrams
Component Connector End Views - Continued
Throttle Actuator Control (TAC) Module (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3842
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3843
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Engine Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 2 of 2
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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Engine Control Module: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Engine Control Module: Connector Views
Component Connector End Views
Electronic Control Module (ECM) - X1 (LNJ)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 1 To 37)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 38 To 73)
Electronic Control Module (ECM) - X2 (LNJ)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 1 To 36)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 37 To 80)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The engine control module (ECM) interacts with many emission related components and systems,
and monitors the emission related components and systems for deterioration. OBD II diagnostics
monitor the system performance and a diagnostic trouble code (DTC) sets if the system
performance degrades.
The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type.
A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions
related DTC.
The ECM is in the engine compartment. The ECM is the control center of the engine controls
system. The ECM controls the following components:
* The fuel injection system
* The ignition system
* The emission control systems
* The on-board diagnostics
* The A/C and fan systems
* The throttle actuation control (TAC) system
The ECM constantly monitors the information from various sensors and other inputs, and controls
the systems that affect the vehicle performance and the emissions. The ECM also performs
diagnostic tests on various parts of the system. The ECM can recognize operational problems and
alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The
condition area is identified by the particular DTC that is set. This aids the technician in making
repairs.
ECM Function
The engine control module (ECM) can supply 5 volts or 12 volts to the various sensors or switches.
This is done through pull-up resistors to the regulated power supplies within the ECM. In some
cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is
too low. Therefore, a DMM with at least 10 megaohms input impedance is required in order to
ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through the
transistors or a device called an output driver module.
EEPROM
The electronically erasable programmable read only memory (EEPROM) is a permanent memory
that is physically part of the engine control module (ECM). The EEPROM contains program and
calibration information that the ECM needs in order to control the powertrain operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in
order to reprogram the ECM.
Data Link Connector (DLC)
The data link connector (DLC) is a 16-pin connector that provides the technician a means of
accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan
tool in order to monitor the various serial data parameters, and display the DTC information. The
DLC is located inside of the drivers compartment, underneath the dash.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is
controlled by the engine control module (ECM) and illuminates when the ECM detects a condition
that affects the vehicle emissions.
ECM Service Precautions
The engine control module (ECM), by design, can withstand the normal current draws that are
associated with the vehicle operations. However, care must be used in order to avoid overloading
any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the
ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be
tested with a DMM.
Emissions Diagnosis For State I/M Programs
This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive
levels of the following emissions:
* Hydrocarbons (HC)
* Carbon monoxide (CO)
* Oxides of nitrogen (NOx)
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* Evaporative emission (EVAP) system losses
Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in
excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC
that is associated with the condition.
Aftermarket (Add-On) Electrical And Vacuum Equipment
Notice: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on
vacuum equipment may result in damage to vehicle components or systems.
Notice: Connect any add-on electrically operated equipment to the vehicle's electrical system at the
battery (power and ground) in order to prevent damage to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a
vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No
allowances have been made in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the
powertrain system to malfunction. This may also include equipment not connected to the vehicle
electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing
any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle.
After this is done, if the problem still exists, the problem may be diagnosed in the normal manner.
Electrostatic Discharge (ESD) Damage
Important: In order to prevent possible electrostatic discharge damage to the engine control module
(ECM), DO NOT touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very
low voltage. The electronic components are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can cause damage to some electronic
components.
There are several ways for a person to become statically charged. The most common methods of
charging are by friction and by induction. An example of charging by friction is a person sliding
across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly
charged object and momentarily touches ground. Charges of the same polarity are drained off
leaving the person highly charged with the opposite polarity. Static charges can cause damage,
therefore, it is important to use care when handling and testing electronic components.
Emissions Control Information Label
The underhood Vehicle Emissions Control Information Label contains important emission
specifications and setting procedures. In the upper left corner is the exhaust emission information.
This identifies the year, the manufacturing division of the engine, the displacement of the engine in
liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated
emission components and vacuum hose schematic.
This label is located in the engine compartment of every General Motors vehicle. If the label has
been removed, it can be ordered from GM service parts operations (GMSPO).
Underhood Inspection
Important: This inspection is very important and must be done carefully and thoroughly.
Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing
the cause of an emission test failure. This can often lead to repairing a condition without further
steps. Use the following guidelines when performing an inspection:
* Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
* Inspect any hoses that are difficult to see.
* Inspect all of the wires in the engine compartment for the following conditions:
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Notice:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5000 km (3,000 mi) from the last engine oil change.
Important: It is necessary to record the remaining automatic transmission fluid life. If the
replacement module is not programed with the remaining automatic transmission fluid life, the
automatic transmission fluid life will default to 100 percent. If the replacement module is not
programmed with the remaining automatic transmission fluid life, the automatic transmission fluid
will need to be changed at 83000 km (50,000 mi) from the last automatic transmission fluid change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic
transmission fluid life. Record the remaining engine
oil and the remaining automatic transmission fluid life.
2. Slide the engine control module (ECM) retainer rearward, disengaging the retainer from the
battery shield. 3. Remove the ECM retainer from the top of the battery shield.
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4. Remove the ECM from the retainer. Reposition the ECM out of the way.
5. Disconnect the negative battery cable. 6. Place the battery shield over the battery. 7. Place the
ECM on top of the battery shield. 8. Disconnect the engine wiring harness electrical connectors (2)
from the ECM.
Installation Procedure
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1. Connect the engine wiring harness electrical connectors (2) to the ECM. Reposition the ECM out
of the way. 2. Remove the battery shield from over the battery. 3. Connect the negative battery
cable.
4. Install the ECM to the retainer.
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5. Position the ECM and retainer to the top of the battery shield. 6. Slide the ECM retainer
rearward, engaging the retainer to the battery shield.
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Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuel Pump Relay: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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and Instructions > Page 4025
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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and Instructions > Page 4029
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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and Instructions > Page 4045
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 4065
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 4066
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 2 of 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4074
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4075
Ignition Control Module: Diagrams
Component Connector End Views
Ignition Control Module (ICM) (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement
Ignition Control Module: Service and Repair Ignition Coil/Control Module Replacement
Ignition Coil/Control Module Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
spark plug wires. Note the position from which the wires are removed. 4. Disconnect the ignition
coil/control module electrical connectors. 5. Remove the 4 bolts securing the ignition coil/control
module to the ignition control module bracket. 6. Remove the ignition coil/control module.
Installation Procedure
1. Install the ignition coil/control module to the ignition control module bracket.
Notice: Refer to Fastener Notice.
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Module Replacement > Page 4078
2. Install the 4 bolts securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
3. Connect the ignition coil/control module electrical connectors. 4. Connect the spark plug wires. 5.
Install the injector sight shield. 6. Connect the negative battery cable.
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Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 4079
Ignition Control Module: Service and Repair Ignition Control Module Bracket Replacement
Ignition Control Module Bracket Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
ignition coil/control module electrical connectors. 4. Remove the spark plug wire retainer (1) from
the ignition control module bracket. 5. Remove the 4 bolts securing the ignition coil/control module
to the ignition control module bracket. 6. Position the ignition coil/control module aside out of the
way. 7. Remove the bolt (3) from the fuel injector wire harness bracket (4) and positive crankcase
ventilation (PCV) valve fresh air tube retainer. 8. Remove the engine wire harness retainers from
the ignition control module bracket studs (5).
9. Remove the nut (1) retaining the heater outlet pipe.
10. Lift pipe up slightly to gain access for the removal of the 2 ignition control module bracket bolts.
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Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 4080
11. Remove the ignition control module bracket bolts (2). 12. Remove the ignition control module
bracket nuts (6). 13. Remove the ignition control module bracket.
Installation Procedure
1. Install the ignition control module bracket.
Notice: Refer to Fastener Notice.
2. Install the ignition control module bracket nuts (6).
Tighten the nuts to 25 N.m (18 lb ft).
3. Install the ignition control module bracket bolts (2).
Tighten the bolts to 25 N.m (18 lb ft).
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Modules - Ignition System > Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control
Module Replacement > Page 4081
4. Install the nut (1) retaining the heater outlet pipe.
Tighten the nut to 25 N.m (18 lb ft).
5. Install the engine wire harness retainers to the ignition control module bracket studs (5). 6. Install
the bolt (3) from the fuel injector wire harness bracket (4) and PCV valve fresh air tube retainer.
Tighten the bolts to 5 N.m (44 lb in).
7. Install the ignition coil/control module to the ignition control module bracket. 8. Install the 4 bolts
securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
9. Install the spark plug wire retainer (1) to the ignition control module bracket.
10. Connect the ignition coil/control module electrical connectors. 11. Install the injector sight
shield. 12. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Relay > Component Information > Locations
Ignition Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 4090
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 4091
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 4092
1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4098
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4099
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4100
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4101
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Information and Instructions > Page 4102
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Information and Instructions > Page 4103
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Information and Instructions > Page 4104
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Information and Instructions > Page 4105
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4181
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 4182
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information and Instructions > Page 4183
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 4184
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4185
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4186
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4187
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4188
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 4189
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 4190
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 4195
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Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
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Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
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1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 4211
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 4296
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 4305
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 4306
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Information and Instructions > Page 4307
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Information and Instructions > Page 4308
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
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Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 4315
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
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Information > Specifications > Page 4316
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
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Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 4409
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4410
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 4411
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 4414
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 4415
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 4418
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 4419
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Information and Instructions > Page 4420
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Information and Instructions > Page 4421
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
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Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Level Sensor Replacement - Secondary
Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - Secondary
Fuel Level Sensor Replacement - Secondary
Removal Procedure
Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced.
Obtain a NEW seal prior to beginning this service procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and the float electrical connector. 4. Release the retaining tabs and remove the level sensor by
sliding up.
Installation Procedure
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Level Sensor Replacement - Secondary > Page 4431
1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place. 2. Connect the fuel level sender unit and the float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Level Sensor Replacement - Secondary > Page 4432
Fuel Level Sensor: Service and Repair Primary Fuel Level Sensor Replacement
Primary Fuel Level Sensor Replacement
Removal Procedure
Important: NEW fuel tank module seals are necessary each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and secondary modules prior to beginning this service
procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and float electrical connector from the underside of the top of the pump module. 4. Release the
retaining tabs (1, 2) and remove the level sensor by sliding up.
Installation Procedure
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1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place (1, 2). 2. Connect the fuel level sender unit and float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Fuel Tank Pressure Sensor: Locations
Wheels/Vehicle Underbody Component Views
Rear Axle and Fuel Tank Components
Near The Rear Differential
1 - Rear Differential Clutch Control Module (MH6) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP)
Canister Vent Solenoid 4 - Fuel Sending Unit 5 - Fuel Tank Pressure (FTP) Sensor
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4437
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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4438
Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Remove the fuel tank.
2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure
sensor.
3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4.
Carefully use the screwdrivers to lift and release the sensor from the fuel pump module.
Installation Procedure
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1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor
grommet is fully seated to the pump module.
2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel
tank.
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
Intake Air Temperature Sensor: Specifications
Temperature Versus Resistance
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Page 4443
Intake Air Temperature Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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and Instructions > Page 4453
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 4483
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Sensor Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
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Sensor Replacement - Bank 1 > Page 4555
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
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Sensor Replacement - Bank 1 > Page 4556
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
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Sensor Replacement - Bank 1 > Page 4557
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock
Sensor Replacement - Bank 1 > Page 4558
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 4562
Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LNJ)
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Page 4563
Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
2. Remove the MAP sensor retaining bolt (3) and bracket (2). 3. Remove the MAP sensor (1) and
the MAP sensor port seal if it is still retained in the intake manifold.
Installation Procedure
1. Install the MAP sensor (1) to the intake manifold.
Notice: Refer to Fastener Notice.
2. Install the MAP sensor retaining bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Page 4564
3. Connect the MAP sensor electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
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1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for
the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Exhaust Components (LNJ)
1 - Heated Oxygen Sensor (HO2S) 1 2 - Heated Oxygen Sensor (HO2S) 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Oxygen Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 4574
Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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and Instructions > Page 4575
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 4576
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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and Instructions > Page 4577
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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and Instructions > Page 4578
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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and Instructions > Page 4579
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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and Instructions > Page 4580
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 4581
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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and Instructions > Page 4582
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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and Instructions > Page 4637
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LNJ)
Heated Oxygen Sensor (HO2S) 2 (LNJ)
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Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
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Oxygen and Oxygen Sensor Notice > Page 4676
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
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Oxygen and Oxygen Sensor Notice > Page 4677
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
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Oxygen and Oxygen Sensor Notice > Page 4678
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
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Oxygen and Oxygen Sensor Notice > Page 4679
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
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Oxygen and Oxygen Sensor Notice > Page 4680
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
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Oxygen Sensor 1 Replacement
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 1 Replacement
Heated Oxygen Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector from the heated oxygen sensor (HO2S). 3. Remove the HO2S from the
exhaust manifold.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
1. Apply a small amount of anti-seize compound to the threads of the HO2S.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S to the exhaust manifold.
Tighten the HO2S to 42 N.m (31 lb ft).
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Oxygen Sensor 1 Replacement > Page 4683
3. Connect the engine wiring harness electrical connector to the HO2S. Push in the connector until
a click is heard and pull back to confirm a positive
engagement.
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Oxygen Sensor 1 Replacement > Page 4684
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 Replacement
Heated Oxygen Sensor 2 Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the HO2S 2 harness connector (3).
Important: Silicone based products will contaminate the HO2S. DO NOT use products containing
silicone on or near the HO2S.
3. Use a liquid penetrate before removing the sensor. 4. Remove the HO2S 2 (2) from the exhaust
pipe.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
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Oxygen Sensor 1 Replacement > Page 4685
1. Apply a small amount of anti-seize compound to the threads of the HO2S 2.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S 2 (2).
Tighten the HO2S 2 to 42 N.m (31 lb ft).
3. Connect the HO2S 2 harness connector (3). Push in the connector until a click is heard, then pull
back to confirm a positive engagement. 4. Ensure the HO2S 2 harness pigtail connector is secure
to the chassis.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 4690
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 4691
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Information and Instructions > Page 4692
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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Information and Instructions > Page 4699
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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Information and Instructions > Page 4721
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Information and Instructions > Page 4750
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 4776
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4777
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 4778
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 4779
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4780
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 4782
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 4783
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 4784
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 4785
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 4786
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 4787
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
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Locations > Automatic Transmission Electronic Component Views > Page 4792
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
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Locations > Automatic Transmission Electronic Component Views > Page 4793
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
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Locations > Automatic Transmission Electronic Component Views > Page 4794
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
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Service and Repair > 6T70/6T75 - Automatic Transmission > Page 4797
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
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Service and Repair > 6T70/6T75 - Automatic Transmission > Page 4798
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
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Page 4803
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Page 4804
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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Page 4805
1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 4811
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 4812
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Information and Instructions > Page 4813
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Information and Instructions > Page 4814
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Information and Instructions > Page 4815
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Information and Instructions > Page 4816
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Information and Instructions > Page 4817
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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Information and Instructions > Page 4819
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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Information and Instructions > Page 4820
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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Information and Instructions > Page 4841
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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Information and Instructions > Page 4842
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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Information and Instructions > Page 4843
View of the connector when released from the component.
View of another type of Micro 64 connector.
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Information and Instructions > Page 4844
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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Information and Instructions > Page 4845
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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Information and Instructions > Page 4848
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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Information and Instructions > Page 4850
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Information and Instructions > Page 4853
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Information and Instructions > Page 4855
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Information and Instructions > Page 4859
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Information and Instructions > Page 4860
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information and Instructions > Page 4896
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 4897
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 4898
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 4899
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 4900
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 4901
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 4902
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 4903
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 4904
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 4905
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 4906
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 4907
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 4908
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Information and Instructions > Page 4909
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
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Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Information and Instructions > Page 4960
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Information and Instructions > Page 4963
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Information and Instructions > Page 4965
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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Information and Instructions > Page 4972
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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Information and Instructions > Page 4993
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 5003
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 5012
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Information and Instructions > Page 5013
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Instructions > Page 5068
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Instructions > Page 5209
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Instructions > Page 5210
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Instructions > Page 5212
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Instructions > Page 5214
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 5216
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 5218
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 5219
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Instructions > Page 5221
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 5222
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 5223
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 5224
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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Position Sensor Replacement > Page 5227
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Position Sensor Replacement > Page 5228
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To
Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key
Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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> Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
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> Procedures > Page 5245
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
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> Procedures > Page 5246
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
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> Procedures > Page 5247
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
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> Procedures > Page 5248
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Procedures > Page 5249
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
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> Procedures > Page 5250
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
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Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Page 5258
Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Page 5259
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Page 5260
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Page 5261
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5350
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5351
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5352
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5353
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5354
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5355
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5356
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 5357
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5358
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 5361
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 5362
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 5363
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement Bank 1 > Page 5364
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure.......................................................................................................................................
...............................................384-425 kPa (56-62 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information > Page 5371
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5374
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5375
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned
ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition
reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference
pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference
pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the
primary fuel tank module, eliminating the need for a return pipe from the engine. A returnless fuel
system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to
the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative
emissions.
An electric turbine style fuel pump attaches to the primary fuel tank module inside the fuel tank.
The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator,
and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint
that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of
the primary fuel tank module. The primary fuel tank module contains a reverse flow check valve.
The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the
fuel rail in order to prevent long cranking times.
The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel
pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet
pump and the secondary jet pump through a restrictive orifice located on the pump cover. The
primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates
a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through
the fuel transfer pipe, to the primary side of the fuel tank.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
*
Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 384-425 kPa (56-62 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 5376
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 384-425 kPa
(56-62 psi).
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail.
3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan
tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF with
a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the primary fuel pump
module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the primary fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Replacement - Chassis
* Fuel Hose/Pipes Replacement - Engine Compartment
* Fuel Injector Replacement
* Primary Fuel Tank Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed >
System Information > Specifications
Idle Speed: Specifications
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Inlet Duct Replacement
Removal Procedure
1. Loosen the clamps at both ends of the air cleaner intake duct. 2. Remove the positive crankcase
ventilation (PCV) fresh air pipe from the air cleaner intake duct. 3. Remove the air cleaner intake
duct from the mass air flow (MAF) sensor and throttle body.
Installation Procedure
1. Install the air cleaner intake duct to the MAF sensor and throttle body. 2. Install the PCV fresh air
pipe to the air cleaner intake duct.
Notice: Refer to Fastener Notice.
3. Tighten the clamps at both ends of the air cleaner intake duct.
Tighten the clamps to 4 N.m (35 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Release the clamps (2) on the side of the air cleaner assembly. 4. Remove the air cleaner
assembly lid (1) by tilting to release the lid from the lower housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair > Page 5387
5. Remove the air cleaner element (2) from the lower housing (1).
Installation Procedure
1. Install the air cleaner element (2) into the lower housing (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner
Housing > Air Filter Element > Component Information > Service and Repair > Page 5388
2. Install the air cleaner assembly lid (1) by first engaging the hinge then lower the cover into the
closed position. 3. Fasten the clamps (2) on the side of the air cleaner assembly.
4. Connect the MAF sensor electrical connector. 5. Install the air cleaner intake duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 5394
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 5395
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Procedures > Page 5396
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
..................................................................1-2-3-4-5-6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
........................4,018 ohm per meter(1,225 ohmper ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 5403
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Refer to the list below
for items to be inspected.
1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2.
Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following
conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the
wire and the component connected to the wire should be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 5404
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the injector sight shield.
Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug
boot only. Do not pull on the spark plug wire or the wire could be damaged.
2. Remove the spark plug wires (1) from the left side spark plugs. 3. Remove the spark plug wires
from the retaining clips (2).
4. Remove the spark plug wires (1) from the right side spark plugs. 5. Remove the spark plug wires
from the retaining clips (2). 6. Remove the spark plug wires from the ignition coil/control module. 7.
Remove the spark plug wires from the engine. 8. If you are replacing the spark plug wires, transfer
any of the following components:
* Boot heat shields
* Spark plug wire conduit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 5405
* Spark plug wire retaining clips
Installation Procedure
1. Install the spark plug wires (1) to the ignition coil/control module. 2. Install the spark plug wires
(1) to the right side spark plugs. 3. Install the spark plug wires to the retaining clips (2).
4. Install the spark plug wires (1) to the left side spark plugs. 5. Install the spark plug wires to the
retaining clips (2). 6. Install the injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark
Plug Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark
Plug Wire Warranty Extension > Page 5414
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark
Plug Wire Warranty Extension > Page 5415
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark
Plug Wire Warranty Extension > Page 5416
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 5422
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 5423
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 >
Campaign - Spark Plug Wire Warranty Extension > Page 5424
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 5425
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.........................................................1.52 mm (0.60 in)
Spark Plug Torque
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
Spark Plug Type
............................................................................................................................................
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 5426
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling-Colder plug
- Pre-ignition causing spark plug and/or engine damage-Hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 5427
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal
combustion by-products from fuels with additives.
* Carbon fouled-Dry, fluffy, black carbon or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 5428
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: Observe the following service precautions:
* Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from
a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads.
* Clean the spark plug recess area before removing the spark plug. Failure to do so can result in
engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the
cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.
* Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either
hotter or colder than those specified for the vehicle. Installing spark plugs of another type can
severely damage the engine.
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs (1) from the cylinder head.
Installation Procedure
Notice: It is important to check the gap of all new and reconditioned spark plugs before installation.
Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an
accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor
engine performance and may even damage the engine.
1. Gap the spark plugs to the specifications. Refer to Ignition System Specifications.
Notice: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if
necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can
cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque
specifications carefully. Over or under-tightening can also cause severe damage to engine or spark
plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 5429
Notice: Refer to Component Fastener Tightening Notice.
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
2. Install the spark plugs to the cylinder head.
Tighten the spark plugs to 15 N.m (11 lb ft).
3. Install the spark plug wires to the spark plugs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications
Compression Check: Specifications
The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading
should be less than
................................................................................................................................................... 689
kPa (100 psi).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression
Check > System Information > Specifications > Page 5433
Compression Check: Testing and Inspection
Engine Compression Test
A compression pressure test of the engine cylinders determines the condition of the rings, the
valves, and the head gasket.
Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse
block. Refer to Electrical Center Identification Views .
1. Disable the ignition. 2. Disable the fuel systems. 3. Remove the spark plugs from all the
cylinders. 4. Remove the air duct from the throttle body. 5. Block the throttle plate in the open
position. 6. Measure the engine compression, using the following procedure:
1. Firmly install the compression gauge to the spark plug hole. 2. Have an assistant crank the
engine through at least 4 compression strokes in the testing cylinder. 3. Record the readings on the
gauge at each stroke. 4. Disconnect the gauge. 5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
* The lowest reading should not be less than 70 percent of the highest reading.
* No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements:
* When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
* When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, the piston rings may be the cause.
* If the compression improves considerably with the addition of three squirts of oil, the piston rings
may be the cause.
* When the compression is low on the first stroke and does not build up in the following strokes, the
valves may be the cause.
* The addition of oil does not affect the compression, the valves may be the cause.
* When the compression is low on two adjacent cylinders, or coolant is present in the crankcase,
the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body. 11. Install the spark plugs. 12. Install the Powertrain
Control Module (PCM) fuse. 13. Install the ignition fuse to the I/P fuse block.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 5438
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 5439
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Sensor > Component Information > Locations > Page 5440
1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5446
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5447
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5448
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5449
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5450
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5451
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5452
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5453
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5454
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5455
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
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View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Component Information > Diagrams > Diagram Information and Instructions > Page 5509
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5510
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5511
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 5512
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5513
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5514
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5515
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Component Information > Diagrams > Diagram Information and Instructions > Page 5516
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5517
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5519
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5520
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5521
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5522
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5523
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5524
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5525
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5526
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Component Information > Diagrams > Diagram Information and Instructions > Page 5528
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5532
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5533
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5534
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5535
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5536
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5537
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5538
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5539
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5540
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5541
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5542
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5543
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5544
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 5545
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 5546
1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications
Intake Air Temperature Sensor: Specifications
Temperature Versus Resistance
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 5550
Intake Air Temperature Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 5551
Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 5555
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 5556
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor >
Component Information > Locations > Page 5557
1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
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5562
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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Disclaimer
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Body Control Module: Locations
Instrument Panel/Center Console Component Views
Lower Center Instrument Panel Components
1 - Body Control Module (BCM) 2 - Instrument Panel Harness 3 - Center Instrument Panel Support
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Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Body Control Module (BCM) X2
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Body Control Module (BCM) X3
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Body Control Module (BCM) X4
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Body Control Module (BCM) X5
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Body Control Module (BCM) X6
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Body Control Module (BCM) X7
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Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important: If data is not retrieved from the malfunctioning body control module (BCM), additional
time will be required to program the replacement BCM.
1. Retrieve data from the malfunctioning BCM. 2. Rotate the ignition switch to the OFF position.
3. Remove the radio bezel. 4. Disconnect the BCM electrical harnesses. 5. Remove the BCM from
the instrument panel (I/P) retainer:
1. Pry the BCM tabs from the locking tabs on the underside of the restraint. 2. Slide the BCM out of
the retainer.
Installation Procedure
1. Install the BCM. 2. Install the radio bezel. 3. Slide the BCM tabs into the slots in the I/P retainer
until the tabs lock into place. 4. Connect the electrical connectors. 5. Program a new or a
remanufactured BCM.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Component Information > Diagrams > Diagram Information and Instructions > Page 5625
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Component Information > Diagrams > Diagram Information and Instructions > Page 5629
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5679
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
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Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Sensor/Switch (For Computer) > Component Information > Specifications > Page 5686
Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
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Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 5696
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5769
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5770
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5771
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5772
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5773
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5774
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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Component Information > Diagrams > Diagram Information and Instructions > Page 5775
The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5776
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5777
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5778
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5779
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5780
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5781
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5782
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5783
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 5784
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5785
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5786
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5787
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5788
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5789
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5790
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5791
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 5792
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5795
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5796
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Data Link Connector: Locations
Instrument Panel/Center Console Component Views
Lower Left Side Instrument Panel Components
1 - JX200 2 - Instrument Panel Harness 3 - Data Link Connector (DLC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Data Link Connector (DLC)
Data Link Connector: Diagrams Data Link Connector (DLC)
Component Connector End Views
Data Link Connector (DLC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Data Link Connector (DLC) > Page 5802
Data Link Connector: Diagrams Data Link Resistor
Component Connector End Views
Data Link Resistor (-MH6)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Description and Operation
Electronic Throttle Actuator: Description and Operation
Throttle Actuator Control (TAC) System Description
The engine control module (ECM) is the control center for the throttle actuator control (TAC)
system. The ECM determines the driver's intent based on input from the accelerator pedal position
sensors, then calculates the appropriate throttle response based on the throttle position sensors.
The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle
actuator motor. The throttle blade is spring loaded in both directions, and the default position is
slightly open.
Modes Of Operation
Normal Mode
During the operation of the TAC system, several modes, or functions, are considered normal. The
following modes may be entered during normal operations:
* Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value.
* Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle
position value. In order to learn the minimum throttle position value, the throttle blade is moved to
the Closed position.
* Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle
position, the ice break mode is entered. During the ice break mode, the ECM commands the
maximum pulse width several times to the throttle actuator motor in the closing direction.
* Battery saver mode-After a predetermined time without engine RPM, the ECM commands the
battery saver mode. During the battery saver mode, the TAC module removes the voltage from the
motor control circuits, which removes the current draw used to maintain the idle position and allows
the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine
power mode. Reduced engine power may cause one or more of the following conditions:
* Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control,
however, the vehicle acceleration is limited.
* Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control,
however, the maximum throttle opening is limited.
* Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will
return to the spring loaded default position.
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Component Information > Description and Operation > Page 5806
* Forced idle mode-The ECM will perform the following actions:
- Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if
the throttle is turned OFF.
- Ignore the accelerator pedal input.
* Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations
Electronic Throttle Control Module: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations > Page 5810
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 1 of 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations > Page 5811
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Module > Component Information > Locations > Page 5812
Electronic Throttle Control Module: Diagrams
Component Connector End Views - Continued
Throttle Actuator Control (TAC) Module (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5817
results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 5818
Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Engine Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 2 of 2
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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Engine Control Module: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Engine Control Module: Connector Views
Component Connector End Views
Electronic Control Module (ECM) - X1 (LNJ)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 1 To 37)
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Electronic Control Module (ECM) - X1 (LNJ) (Pin 38 To 73)
Electronic Control Module (ECM) - X2 (LNJ)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 1 To 36)
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Electronic Control Module (ECM) - X2 (LNJ) (Pin 37 To 80)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The engine control module (ECM) interacts with many emission related components and systems,
and monitors the emission related components and systems for deterioration. OBD II diagnostics
monitor the system performance and a diagnostic trouble code (DTC) sets if the system
performance degrades.
The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type.
A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions
related DTC.
The ECM is in the engine compartment. The ECM is the control center of the engine controls
system. The ECM controls the following components:
* The fuel injection system
* The ignition system
* The emission control systems
* The on-board diagnostics
* The A/C and fan systems
* The throttle actuation control (TAC) system
The ECM constantly monitors the information from various sensors and other inputs, and controls
the systems that affect the vehicle performance and the emissions. The ECM also performs
diagnostic tests on various parts of the system. The ECM can recognize operational problems and
alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The
condition area is identified by the particular DTC that is set. This aids the technician in making
repairs.
ECM Function
The engine control module (ECM) can supply 5 volts or 12 volts to the various sensors or switches.
This is done through pull-up resistors to the regulated power supplies within the ECM. In some
cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is
too low. Therefore, a DMM with at least 10 megaohms input impedance is required in order to
ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through the
transistors or a device called an output driver module.
EEPROM
The electronically erasable programmable read only memory (EEPROM) is a permanent memory
that is physically part of the engine control module (ECM). The EEPROM contains program and
calibration information that the ECM needs in order to control the powertrain operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in
order to reprogram the ECM.
Data Link Connector (DLC)
The data link connector (DLC) is a 16-pin connector that provides the technician a means of
accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan
tool in order to monitor the various serial data parameters, and display the DTC information. The
DLC is located inside of the drivers compartment, underneath the dash.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is
controlled by the engine control module (ECM) and illuminates when the ECM detects a condition
that affects the vehicle emissions.
ECM Service Precautions
The engine control module (ECM), by design, can withstand the normal current draws that are
associated with the vehicle operations. However, care must be used in order to avoid overloading
any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the
ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be
tested with a DMM.
Emissions Diagnosis For State I/M Programs
This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive
levels of the following emissions:
* Hydrocarbons (HC)
* Carbon monoxide (CO)
* Oxides of nitrogen (NOx)
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* Evaporative emission (EVAP) system losses
Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in
excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC
that is associated with the condition.
Aftermarket (Add-On) Electrical And Vacuum Equipment
Notice: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on
vacuum equipment may result in damage to vehicle components or systems.
Notice: Connect any add-on electrically operated equipment to the vehicle's electrical system at the
battery (power and ground) in order to prevent damage to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a
vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No
allowances have been made in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the
powertrain system to malfunction. This may also include equipment not connected to the vehicle
electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing
any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle.
After this is done, if the problem still exists, the problem may be diagnosed in the normal manner.
Electrostatic Discharge (ESD) Damage
Important: In order to prevent possible electrostatic discharge damage to the engine control module
(ECM), DO NOT touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very
low voltage. The electronic components are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can cause damage to some electronic
components.
There are several ways for a person to become statically charged. The most common methods of
charging are by friction and by induction. An example of charging by friction is a person sliding
across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly
charged object and momentarily touches ground. Charges of the same polarity are drained off
leaving the person highly charged with the opposite polarity. Static charges can cause damage,
therefore, it is important to use care when handling and testing electronic components.
Emissions Control Information Label
The underhood Vehicle Emissions Control Information Label contains important emission
specifications and setting procedures. In the upper left corner is the exhaust emission information.
This identifies the year, the manufacturing division of the engine, the displacement of the engine in
liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated
emission components and vacuum hose schematic.
This label is located in the engine compartment of every General Motors vehicle. If the label has
been removed, it can be ordered from GM service parts operations (GMSPO).
Underhood Inspection
Important: This inspection is very important and must be done carefully and thoroughly.
Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing
the cause of an emission test failure. This can often lead to repairing a condition without further
steps. Use the following guidelines when performing an inspection:
* Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
* Inspect any hoses that are difficult to see.
* Inspect all of the wires in the engine compartment for the following conditions:
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Notice:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5000 km (3,000 mi) from the last engine oil change.
Important: It is necessary to record the remaining automatic transmission fluid life. If the
replacement module is not programed with the remaining automatic transmission fluid life, the
automatic transmission fluid life will default to 100 percent. If the replacement module is not
programmed with the remaining automatic transmission fluid life, the automatic transmission fluid
will need to be changed at 83000 km (50,000 mi) from the last automatic transmission fluid change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic
transmission fluid life. Record the remaining engine
oil and the remaining automatic transmission fluid life.
2. Slide the engine control module (ECM) retainer rearward, disengaging the retainer from the
battery shield. 3. Remove the ECM retainer from the top of the battery shield.
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4. Remove the ECM from the retainer. Reposition the ECM out of the way.
5. Disconnect the negative battery cable. 6. Place the battery shield over the battery. 7. Place the
ECM on top of the battery shield. 8. Disconnect the engine wiring harness electrical connectors (2)
from the ECM.
Installation Procedure
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1. Connect the engine wiring harness electrical connectors (2) to the ECM. Reposition the ECM out
of the way. 2. Remove the battery shield from over the battery. 3. Connect the negative battery
cable.
4. Install the ECM to the retainer.
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5. Position the ECM and retainer to the top of the battery shield. 6. Slide the ECM retainer
rearward, engaging the retainer to the battery shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Service and Repair > Fuel Level Sensor Replacement - Secondary
Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - Secondary
Fuel Level Sensor Replacement - Secondary
Removal Procedure
Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced.
Obtain a NEW seal prior to beginning this service procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and the float electrical connector. 4. Release the retaining tabs and remove the level sensor by
sliding up.
Installation Procedure
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1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place. 2. Connect the fuel level sender unit and the float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Fuel Level Sensor: Service and Repair Primary Fuel Level Sensor Replacement
Primary Fuel Level Sensor Replacement
Removal Procedure
Important: NEW fuel tank module seals are necessary each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and secondary modules prior to beginning this service
procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and float electrical connector from the underside of the top of the pump module. 4. Release the
retaining tabs (1, 2) and remove the level sensor by sliding up.
Installation Procedure
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1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place (1, 2). 2. Connect the fuel level sender unit and float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor
> Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Wheels/Vehicle Underbody Component Views
Rear Axle and Fuel Tank Components
Near The Rear Differential
1 - Rear Differential Clutch Control Module (MH6) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP)
Canister Vent Solenoid 4 - Fuel Sending Unit 5 - Fuel Tank Pressure (FTP) Sensor
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> Component Information > Locations > Page 5946
Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Remove the fuel tank.
2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure
sensor.
3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4.
Carefully use the screwdrivers to lift and release the sensor from the fuel pump module.
Installation Procedure
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1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor
grommet is fully seated to the pump module.
2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel
tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator
- Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus >
Component Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information Bus: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information Bus: Description and Operation
Data Link Communications Description and Operation
Circuit Description
The communication among control modules is performed primarily through the GMLAN high speed
serial data circuit and the GMLAN low speed serial data circuits. The modules that need real time
communication are attached to the high speed GMLAN network. The body control module (BCM) is
the serial data gateway between the networks. The purpose of the gateway is to translate serial
data messages between the GMLAN high speed buss and the GMLAN low speed buss. The
controller area network (CAN) is another serial data communication network used on this vehicle
which is dedicated to the electronic brake control module (EBCM) subsystem for stabilization.
Below are more detailed descriptions of the individual networks. The gateway will interact with each
network according to that network's transmission protocol. Refer to Body Control System
Description and Operation for more information about the gateway.
GMLAN High Speed Circuit Description
Important: A loss of serial data DTC does not represent a failure of the module that the code is set
in.
The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN
serial data circuit. The serial data is transmitted on two twisted wires that allow speed up to 500
Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine
control module (ECM) and the other is after the BCM in either the AWD module or a separate
resistor connector assembly. The resistors are used to reduce noise on the High Speed GMLAN
buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed
GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes
from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive
transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to
the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN
serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network
management supports selective start up and is based on virtual networks. A virtual network is a
collection of signals started in response to a vehicle event. The starting of a virtual network signifies
that a particular aspect of the vehicles functionality has been requested. A virtual network is
supported by virtual devices, which represents a collection of signals owned by a single physical
device. So, any physical device can have one or more virtual devices. The signal supervision is the
process of determining whether an expected signal is being received or not. Failsofting is the ability
to substitute a signal with a default value or a default algorithm, in the absence of a valid signal.
Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the
application will set a no communication code against the respective virtual device. This code is
mapped on the Tech 2 screen as a code against the physical device.
GMLAN Low Speed Circuit Description
The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial
data circuit. The serial data is transmitted over a single wire to the appropriate control modules.
The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating
conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pulse train sent
out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this
creates a dominant logic state or 0 on the buss. When the buss is pulled low, 0 volts, it is translated
as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed
serial data buss, a voltage wake up pulse is sent out over the buss, the voltage level of the pules is
+10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as
described in the previous paragraph. The modules on the GMLAN low speed serial data buss are
connected to the buss in a parallel configuration.
Controller Area Network (CAN) Description
The EBCM communicates with the yaw rate sensor and the steering wheel angle sensor
exclusively, when equipped. This serial data system does not communicate with the scan tool
however; there are loss of communication DTCs for this system which set in the EBCM. The yaw
rate sensor and the steering wheel angle sensors are in effect modules, exchanging essential
information with the EBCM. For more information about these sensors refer to ABS Description and
Operation.
Data Link Connector (DLC)
The data link connector (DLC) is a standardized 16-cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Pin 1 GMLAN low speed communications terminal
* Pin 4 Scan tool power ground terminal
* Pin 5 Common signal ground terminal
* Pin 6 High speed GMLAN serial data bus (+) terminal
* Pin 7
* Pin 14 High speed GMLAN serial data bus (-) terminal
* Pin 16 Scan tool power, battery positive voltage terminal
Serial Data Reference
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The scan tool communicates over the various busses on the vehicle. When a scan tool is installed
on a vehicle, the scan tool will try to communicate with every module that could be optioned into
the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that
options control module. In order to avert misdiagnoses of No Communication with a specific
module, refer to Data Link References for a list of modules, the busses they communicate with, and
the RPO codes for a specific module. See: Testing and Inspection/Component Tests and General
Diagnostics
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Data Communications
Begin the system diagnosis with Diagnostic System Check - Vehicle. The Diagnostic System
Check - Vehicle will provide the following information:
* The identification of the control modules which are not communicating
* The identification of any stored diagnostic trouble codes (DTCs) and their status See: Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin
vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.
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Information Bus: Symptom Related Diagnostic Procedures
Symptoms - Data Communications
Symptoms - Data Communications
Important: The following steps must be completed before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle before using the symptom tables in order to
verify that all of the following are true:
* There are no DTCs set.
* The control modules can communicate via the serial data links. See: Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Data Link Communications Description and
Operation.
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the systems.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests
and General Diagnostics
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Scan Tool Does Not Power Up
* Scan Tool Does Not Communicate with High Speed GMLAN Device
* Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
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Modules connected to the high speed GMLAN serial data circuits monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The
high speed GMLAN serial data circuits must be operational for the vehicle to start due to body
control module (BCM) and engine control module (ECM)/powertrain control module (PCM)
communications. The theft deterrent module and ECM/PCM exchange information using the BCM
as the gateway module allowing communication between the high and low speed serial data
busses. The low speed GMLAN serial data circuit must also be operational for vehicle starting.
Diagnostic Aids
* Use the Data Link References to identify the high speed GMLAN serial data modules.
* This test is used for a total high speed GMLAN communication failure. If only one module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate.
* The engine will not start when there is a total malfunction of the high speed GMLAN serial data
bus. The following conditions may cause a total loss of high speed GMLAN data communication:
- A short between high speed GMLAN (+) and high speed GMLAN (-) circuits
- Any of the high speed GMLAN serial data circuits shorted to ground or voltage
- A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN
circuits
Circuit/System Testing
1. Test for less than 1 ohm of resistance between the DLC ground circuit terminal 5 and ground.
‹› If greater than 1 ohm, test the ground circuit for open/high resistance.
2. Ignition OFF, disconnect the harness connector of the BCM. 3. Ignition ON, test for battery
voltage between each voltage input circuit of the BCM and ground.
‹› If less than battery voltage, test each voltage output circuit of the BCM for a short to ground, and
each voltage input circuit of the BCM for a
short to ground or and open/high resistance. If the circuits test normal, replace the faulty module.
4. Test for less than 1 ohm of resistance between each ground circuit of the BCM and ground.
‹› If greater than 1 ohm, repair the ground circuit for an open/high resistance.
5. Attempt to communicate with the electronic brake control module (EBCM). Communication
should not be available.
‹› If communication is established, test or replace the resistor.
6. Ignition OFF, disconnect the harness connector of the suspension control module. 7. Attempt to
communicate with the EBCM. Communication should not be available.
‹› If communication is established, test the serial data circuits for a short between them, short to
ground or a short to voltage between the
suspension control module and the terminator resistor. If the circuits test normal, replace the
suspension control module.
8. Ignition OFF, disconnect the harness connector of the distance sensing cruise control module. 9.
Attempt to communicate with the EBCM. Communication should not be available.
‹› If communication is established, replace the cruise control module.
10. Ignition OFF, disconnect the harness connector of the vehicle communication interface module
(VCIM). 11. Attempt to communicate with the EBCM. Communication should not be available.
‹› If communication is established, test the serial data circuits for a short between them, short to
ground or a short to voltage between the between
the VCIM and the suspension control module. If the circuits test normal, replace the VCIM.
12. Ignition OFF, disconnect BCM harness connector C3. 13. Test for infinite resistance between
the serial data circuits of BCM harness connector C3 terminal 8 and ground and between BCM
harness
connector C3 terminal 9 and ground.
‹› If less than infinite, test the circuit for a short to ground.
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14. Ignition OFF, disconnect the harness connector of the ECM. Connect the harness connector
C3 of the BCM. 15. Attempt to communicate with the EBCM. Communication should not be
available.
‹› If communication is established, replace the ECM.
16. Ignition OFF, disconnect the harness connector of the transmission control module (TCM). 17.
Attempt to communicate with the EBCM. Communication should not be available.
‹› If communication is established, test the serial data circuits for a short between them, short to
ground or a short to voltage between the TCM
and the ECM. If the circuits test normal, replace the TCM.
18. Ignition OFF, connect the harness connector of the suspension control module. Disconnect the
harness connector of the EBCM. 19. Attempt to communicate with the suspension control module.
Communication should not be available.
‹› If communication is established, test the serial data circuits for a short between them, short to
ground or a short to voltage between the EBCM
and the TCM. If the circuits test normal, replace the EBCM.
20. Ignition OFF, disconnect the harness connector C3 of the BCM. 21. Test for less than 1 volt
between the high speed GMLAN serial data circuits of the DLC and ground.
‹› If greater than 1 volt, test the serial data circuit for a short to voltage.
22. Test for infinite resistance between the high speed GMLAN serial data circuit of the DLC and
ground.
‹› If less than infinite resistance, test the serial data circuit for a short to ground.
23. Test for infinite resistance between the high speed GMLAN serial data (+) and (-) circuits of the
DLC.
‹› If less than infinite resistance, test the serial data circuits for a short between them.
24. If the circuits test normal, replace the BCM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
* GMLAN Wiring Repairs
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Scan Tool Does Not Communicate with Low Speed GMLAN Device
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
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Circuit/System Description
Modules connected to the low speed GMLAN serial data circuit monitor for serial data
communications during normal vehicle operation. Operating information and commands are
exchanged among the modules when the ignition switch is in any position other than OFF. The low
speed GMLAN serial data circuit must be operational for the vehicle to start so the vehicle theft
deterrent (VTD) module and body control module (BCM) can communicate. The low speed GMLAN
serial data circuit uses SP 200 as the common connection between the modules and the data link
connector (DLC).
Diagnostic Aids
* Use the Data Link References to identify the low speed GMLAN serial data modules.
* This test is used for a total low speed GMLAN communication failure. If only one module is not
communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use
DTC U0100-U0299 for diagnostics.
* An open in the low speed GMLAN serial data circuit between the splice pack and a module will
only effect the specific module. This type of failure will set a loss of communication DTC for each
module effected, and the other modules will still communicate.
* An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the
vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of
communicating with the vehicle, a message on the scan tool will indicate "no CANdi module
detected" and will not communicate.
* An open between the DLC and SP 200 will only effect the communication with the scan tool. The
vehicle modules will still communicate, and the vehicle will start.
* The engine will not start when there is a total malfunction of the low speed GMLAN serial data
circuit. The following conditions may cause a total loss of low speed GMLAN data communication:
- The low speed GMLAN serial data circuit shorted to ground or voltage.
- A module internal malfunction that causes a short to voltage or ground on the low speed GMLAN
circuit.
Circuit/System Testing
1. Test for less than 1 ohm of resistance between the DLC ground circuit terminal 5 and ground.
‹› If greater than 1 ohm, test the ground circuit for open/high resistance.
2. Ignition OFF, disconnect the harness connector (splice pack comb) at SP 200. Install a 3-amp
fused jumper wire between pin A and pin M of SP
200, harness side.
3. Ignition ON, with a scan tool, attempt to communicate with the BCM. Communication should be
available.
‹› If no communication, test the following circuits: serial data circuit for a short to ground, a short to
voltage or an open/high resistance between
the BCM and DLC, BCM voltage inputs for open/high resistance or short to ground, BCM grounds
for open/high resistance. If the circuits test normal, replace the BCM.
4. Install another 3-amp fused jumper wire to pin A of SP 200, harness side. 5. Use the other end
of the jumper wire to connect all other pins, harness side, one at a time and verify that low speed
communication remains
available to the BCM.
‹› If low speed communication is interrupted after connecting an individual module at SP 200, test
the serial data circuit between SP 200 and the
last module connected for a short to ground and short to voltage. If the circuit tests normal, replace
the module that caused no communication.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
* GMLAN Wiring Repairs
Scan Tool Does Not Power Up
Scan Tool Does Not Power Up
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using the diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
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Circuit/System Description
The data link connector (DLC) is a standardized 16 cavity connector. Connector design and
location is dictated by an industry wide standard, and is required to provide the following:
* Scan tool power battery positive voltage at terminal 16
* Scan tool power ground at terminal 4
* Common signal ground at terminal 5
Diagnostic Aids
* The scan tool will power up with the ignition OFF. Some modules however, will not communicate
unless the ignition is ON and the power mode master (PMM) module sends the appropriate power
mode message.
* If the battery positive voltage, ground circuits and connections of the DLC are functioning
properly, the malfunction must be due to the scan tool/CANdi module.
Circuit/System Testing
1. Ignition ON, test for battery voltage between the battery positive voltage circuit of the DLC and
ground.
‹› If less than battery voltage, repair the voltage supply circuit for a short to ground or an open/high
resistance.
2. Test for less than 1 ohm of resistance between the ground circuit of the DLC and ground.
‹› If greater than 1 ohm, repair the ground circuit for an open/high resistance.
3. If all tests normal, refer to the scan tool/CANdi module user guide.
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Information Bus: Component Tests and General Diagnostics
Data Link References
This table identifies which serial data link that a particular module uses for in-vehicle data
transmission. Some modules may use more than one data link to communicate. Some modules
may have multiple communication circuits passing through them without actively communicating on
that data link. This table is used to assist in correcting a communication malfunction. For the
description and operation of these serial data communication circuits refer to Data Link
Communications Description and Operation.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Service and Repair > Knock Sensor Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 6174
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 6177
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated.
^ If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an
open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the
IPC.
2. Ignition OFF, disconnect connector X1 at the ECM. 3. Ignition ON, verify that the MIL is not
illuminated.
^ If the MIL is illuminated, inspect the MIL control circuit for a short to ground. If the circuit tests
normal, replace the IPC.
4. Ignition ON, verify that the MIL illuminates with a 3A fused jumper wire between the MIL control
circuit, ECM terminal X1-68, and ground.
^ If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the ECM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and
Procedures
* Instrument Cluster Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LNJ)
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Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
2. Remove the MAP sensor retaining bolt (3) and bracket (2). 3. Remove the MAP sensor (1) and
the MAP sensor port seal if it is still retained in the intake manifold.
Installation Procedure
1. Install the MAP sensor (1) to the intake manifold.
Notice: Refer to Fastener Notice.
2. Install the MAP sensor retaining bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
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3. Connect the MAP sensor electrical connector.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor >
Component Information > Service and Repair
Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
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1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for
the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Exhaust Components (LNJ)
1 - Heated Oxygen Sensor (HO2S) 1 2 - Heated Oxygen Sensor (HO2S) 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 6292
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 6295
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Component Information > Diagrams > Diagram Information and Instructions > Page 6296
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 6297
Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LNJ)
Heated Oxygen Sensor (HO2S) 2 (LNJ)
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Component Information > Diagrams > Diagram Information and Instructions > Page 6298
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 6301
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 6302
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service Precautions > Heated Oxygen and Oxygen Sensor Notice > Page 6304
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
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Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor 1 Replacement
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 1 Replacement
Heated Oxygen Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector from the heated oxygen sensor (HO2S). 3. Remove the HO2S from the
exhaust manifold.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
1. Apply a small amount of anti-seize compound to the threads of the HO2S.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S to the exhaust manifold.
Tighten the HO2S to 42 N.m (31 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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3. Connect the engine wiring harness electrical connector to the HO2S. Push in the connector until
a click is heard and pull back to confirm a positive
engagement.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
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Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 Replacement
Heated Oxygen Sensor 2 Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the HO2S 2 harness connector (3).
Important: Silicone based products will contaminate the HO2S. DO NOT use products containing
silicone on or near the HO2S.
3. Use a liquid penetrate before removing the sensor. 4. Remove the HO2S 2 (2) from the exhaust
pipe.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor >
Component Information > Service and Repair > Heated Oxygen Sensor 1 Replacement > Page 6310
1. Apply a small amount of anti-seize compound to the threads of the HO2S 2.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S 2 (2).
Tighten the HO2S 2 to 42 N.m (31 lb ft).
3. Connect the HO2S 2 harness connector (3). Push in the connector until a click is heard, then pull
back to confirm a positive engagement. 4. Ensure the HO2S 2 harness pigtail connector is secure
to the chassis.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Body
Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
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During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
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Disclaimer
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Body Control Module: Locations
Instrument Panel/Center Console Component Views
Lower Center Instrument Panel Components
1 - Body Control Module (BCM) 2 - Instrument Panel Harness 3 - Center Instrument Panel Support
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Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
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Body Control Module (BCM) X2
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Body Control Module (BCM) X3
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Body Control Module (BCM) X4
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Body Control Module (BCM) X5
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Body Control Module (BCM) X6
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Body Control Module (BCM) X7
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Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important: If data is not retrieved from the malfunctioning body control module (BCM), additional
time will be required to program the replacement BCM.
1. Retrieve data from the malfunctioning BCM. 2. Rotate the ignition switch to the OFF position.
3. Remove the radio bezel. 4. Disconnect the BCM electrical harnesses. 5. Remove the BCM from
the instrument panel (I/P) retainer:
1. Pry the BCM tabs from the locking tabs on the underside of the restraint. 2. Slide the BCM out of
the retainer.
Installation Procedure
1. Install the BCM. 2. Install the radio bezel. 3. Slide the BCM tabs into the slots in the I/P retainer
until the tabs lock into place. 4. Connect the electrical connectors. 5. Program a new or a
remanufactured BCM.
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Electronic Throttle Control Module: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 1 of 2 (LNJ)
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1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Electronic Throttle Control Module: Diagrams
Component Connector End Views - Continued
Throttle Actuator Control (TAC) Module (LNJ)
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine
Controls - Aftermarket Accessory Usage
Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory
Usage
INFORMATION
Bulletin No.: 04-06-04-054B
Date: November 18, 2010
Subject: Info - Non-GM Parts and Accessories (Aftermarket)
Models:
2011 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed
Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate
Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System).
The recent rise and expansion of companies selling non-GM parts and accessories has made it
necessary to issue this reminder to dealers regarding GM's policy on the use and installation of
these aftermarket components.
When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to
use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs,
special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the
same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty
repairs, special policy repairs or any repairs paid for by GM.
During a warranty repair, if a GM original equipment part is not available through GM Customer
Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources,
the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order
the circumstances surrounding why non-GM parts were used. The dealer must give customers
written notice, prior to the sale or service, that such parts or accessories are not marketed or
warranted by General Motors.
It should also be noted that dealers modifying new vehicles and installing equipment, parts and
accessories obtained from sources not authorized by GM are responsible for complying with the
National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed
by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design
characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully
understand that non-GM approved parts may not have been validated, tested or certified for use.
This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part
failure occurs as the result of the installation or use of a non-GM approved part, the warranty will
not be honored.
A good example of non-authorized modification of vehicles is the result of an ever increasing
supply of aftermarket devices available to the customer, which claim to increase the horsepower
and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to
one or more of the following modifications:
- Propane injection
- Nitrous oxide injection
- Additional modules (black boxes) that connect to the vehicle wiring systems
- Revised engine calibrations downloaded for the engine control module
- Calibration modules which connect to the vehicle diagnostic connector
- Modification to the engine turbocharger waste gate
Although the installation of these devices, or modification of vehicle components, can increase
engine horsepower and torque, they may also negatively affect the engine emissions, reliability
and/or durability. In addition, other powertrain components, such as transmissions, universal joints,
drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the
installation of these devices.
General Motors does not support or endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or
06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for
calibration verification.
These same policies apply as they relate to the use of non-GM accessories. Damage or failure
from the use or installation of a non-GM accessory will not be covered under warranty. Failure
resulting from the alteration or modification of the vehicle, including the cutting, welding or
disconnecting of the vehicle's original equipment parts and components will void the warranty.
Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal
inquiry at either the local, state or federal level that
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results from the alteration or modification of a vehicle using non-GM approved parts or accessories.
Dealers should be especially cautious of accessory companies that claim the installation of their
product will not void the factory warranty. Many times these companies have even given direction
on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from
finding out that is has been installed.
Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada
by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair
is to be made on the vehicle, even with the installation of such non-GM approved components, the
customer is to be made aware of General Motors position on this issue and is to sign the
appropriate goodwill documentation required by General Motors.
It is imperative for dealers to understand that by installing such devices, they are jeopardizing not
only the warranty coverage, but also the performance and reliability of the customer's vehicle.
Disclaimer
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Engine Control Module: Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
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8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
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2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
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Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
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Engine Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 2 of 2
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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and Instructions
Engine Control Module: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Engine Control Module: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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and Instructions > Page 6444
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and Instructions > Page 6445
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and Instructions > Page 6446
Engine Control Module: Connector Views
Component Connector End Views
Electronic Control Module (ECM) - X1 (LNJ)
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and Instructions > Page 6447
Electronic Control Module (ECM) - X1 (LNJ) (Pin 1 To 37)
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and Instructions > Page 6448
Electronic Control Module (ECM) - X1 (LNJ) (Pin 38 To 73)
Electronic Control Module (ECM) - X2 (LNJ)
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and Instructions > Page 6449
Electronic Control Module (ECM) - X2 (LNJ) (Pin 1 To 36)
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and Instructions > Page 6450
Electronic Control Module (ECM) - X2 (LNJ) (Pin 37 To 80)
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Engine Control Module: Service Precautions
Powertrain Control Module and Electrostatic Discharge Notice
Notice: Do not touch the connector pins or soldered components on the circuit board in order to
prevent possible electrostatic discharge (ESD) damage to the PCM.
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Engine Control Module: Description and Operation
Engine Control Module Description
The engine control module (ECM) interacts with many emission related components and systems,
and monitors the emission related components and systems for deterioration. OBD II diagnostics
monitor the system performance and a diagnostic trouble code (DTC) sets if the system
performance degrades.
The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type.
A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions
related DTC.
The ECM is in the engine compartment. The ECM is the control center of the engine controls
system. The ECM controls the following components:
* The fuel injection system
* The ignition system
* The emission control systems
* The on-board diagnostics
* The A/C and fan systems
* The throttle actuation control (TAC) system
The ECM constantly monitors the information from various sensors and other inputs, and controls
the systems that affect the vehicle performance and the emissions. The ECM also performs
diagnostic tests on various parts of the system. The ECM can recognize operational problems and
alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The
condition area is identified by the particular DTC that is set. This aids the technician in making
repairs.
ECM Function
The engine control module (ECM) can supply 5 volts or 12 volts to the various sensors or switches.
This is done through pull-up resistors to the regulated power supplies within the ECM. In some
cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is
too low. Therefore, a DMM with at least 10 megaohms input impedance is required in order to
ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through the
transistors or a device called an output driver module.
EEPROM
The electronically erasable programmable read only memory (EEPROM) is a permanent memory
that is physically part of the engine control module (ECM). The EEPROM contains program and
calibration information that the ECM needs in order to control the powertrain operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in
order to reprogram the ECM.
Data Link Connector (DLC)
The data link connector (DLC) is a 16-pin connector that provides the technician a means of
accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan
tool in order to monitor the various serial data parameters, and display the DTC information. The
DLC is located inside of the drivers compartment, underneath the dash.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is
controlled by the engine control module (ECM) and illuminates when the ECM detects a condition
that affects the vehicle emissions.
ECM Service Precautions
The engine control module (ECM), by design, can withstand the normal current draws that are
associated with the vehicle operations. However, care must be used in order to avoid overloading
any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the
ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be
tested with a DMM.
Emissions Diagnosis For State I/M Programs
This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive
levels of the following emissions:
* Hydrocarbons (HC)
* Carbon monoxide (CO)
* Oxides of nitrogen (NOx)
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* Evaporative emission (EVAP) system losses
Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in
excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC
that is associated with the condition.
Aftermarket (Add-On) Electrical And Vacuum Equipment
Notice: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on
vacuum equipment may result in damage to vehicle components or systems.
Notice: Connect any add-on electrically operated equipment to the vehicle's electrical system at the
battery (power and ground) in order to prevent damage to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a
vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No
allowances have been made in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the
powertrain system to malfunction. This may also include equipment not connected to the vehicle
electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing
any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle.
After this is done, if the problem still exists, the problem may be diagnosed in the normal manner.
Electrostatic Discharge (ESD) Damage
Important: In order to prevent possible electrostatic discharge damage to the engine control module
(ECM), DO NOT touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very
low voltage. The electronic components are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can cause damage to some electronic
components.
There are several ways for a person to become statically charged. The most common methods of
charging are by friction and by induction. An example of charging by friction is a person sliding
across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly
charged object and momentarily touches ground. Charges of the same polarity are drained off
leaving the person highly charged with the opposite polarity. Static charges can cause damage,
therefore, it is important to use care when handling and testing electronic components.
Emissions Control Information Label
The underhood Vehicle Emissions Control Information Label contains important emission
specifications and setting procedures. In the upper left corner is the exhaust emission information.
This identifies the year, the manufacturing division of the engine, the displacement of the engine in
liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated
emission components and vacuum hose schematic.
This label is located in the engine compartment of every General Motors vehicle. If the label has
been removed, it can be ordered from GM service parts operations (GMSPO).
Underhood Inspection
Important: This inspection is very important and must be done carefully and thoroughly.
Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing
the cause of an emission test failure. This can often lead to repairing a condition without further
steps. Use the following guidelines when performing an inspection:
* Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
* Inspect any hoses that are difficult to see.
* Inspect all of the wires in the engine compartment for the following conditions:
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
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Engine Control Module: Service and Repair
Engine Control Module Replacement
Notice:
* Turn the ignition OFF when installing or removing the control module connectors and
disconnecting or reconnecting the power to the control module (battery cable, powertrain control
module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control
module fuse, jumper cables, etc.) in order to prevent internal control module damage.
* Control module damage may result when the metal case contacts battery voltage. DO NOT
contact the control module metal case with battery voltage when servicing a control module, using
battery booster cables, or when charging the vehicle battery.
* In order to prevent any possible electrostatic discharge damage to the control module, do no
touch the connector pins or the soldered components on the circuit board.
* Remove any debris from around the control module connector surfaces before servicing the
control module. Inspect the control module connector gaskets when diagnosing or replacing the
control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant
intrusion into the control module.
* The replacement control module must be programmed.
Important: It is necessary to record the remaining engine oil life. If the replacement module is not
programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the
replacement module is not programmed with the remaining engine oil life, the engine oil will need
to be changed at 5000 km (3,000 mi) from the last engine oil change.
Important: It is necessary to record the remaining automatic transmission fluid life. If the
replacement module is not programed with the remaining automatic transmission fluid life, the
automatic transmission fluid life will default to 100 percent. If the replacement module is not
programmed with the remaining automatic transmission fluid life, the automatic transmission fluid
will need to be changed at 83000 km (50,000 mi) from the last automatic transmission fluid change.
Removal Procedure
1. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic
transmission fluid life. Record the remaining engine
oil and the remaining automatic transmission fluid life.
2. Slide the engine control module (ECM) retainer rearward, disengaging the retainer from the
battery shield. 3. Remove the ECM retainer from the top of the battery shield.
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4. Remove the ECM from the retainer. Reposition the ECM out of the way.
5. Disconnect the negative battery cable. 6. Place the battery shield over the battery. 7. Place the
ECM on top of the battery shield. 8. Disconnect the engine wiring harness electrical connectors (2)
from the ECM.
Installation Procedure
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1. Connect the engine wiring harness electrical connectors (2) to the ECM. Reposition the ECM out
of the way. 2. Remove the battery shield from over the battery. 3. Connect the negative battery
cable.
4. Install the ECM to the retainer.
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5. Position the ECM and retainer to the top of the battery shield. 6. Slide the ECM retainer
rearward, engaging the retainer to the battery shield.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
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Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Instructions > Page 6473
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Instructions > Page 6561
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 6562
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 6563
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 6564
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 6566
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 6569
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Instructions > Page 6570
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Instructions > Page 6571
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
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Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
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Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
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1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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and Instructions > Page 6586
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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and Instructions > Page 6627
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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and Instructions > Page 6628
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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and Instructions > Page 6629
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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and Instructions > Page 6630
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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and Instructions > Page 6631
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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and Instructions > Page 6632
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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and Instructions > Page 6633
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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and Instructions > Page 6634
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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and Instructions > Page 6635
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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and Instructions > Page 6636
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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and Instructions > Page 6637
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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and Instructions > Page 6638
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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and Instructions > Page 6639
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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and Instructions > Page 6645
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Temperature Versus Resistance
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Coolant Temperature Sensor/Switch (For Computer): Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Coolant Temperature Sensor/Switch (For Computer): Diagrams
Component Connector End Views
Engine Coolant Temperature (ECT) Sensor (LNJ)
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor Replacement
Removal Procedure
1. Drain the engine coolant to a level below the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling (LNJ Static
Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling System Draining and Filling
(LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716 Fill).
2. Remove the fuel injector sight shield. 3. Disconnect the ECT sensor harness connector. 4.
Remove the ECT sensor.
Installation Procedure
Important: Tap out sensor mounting hole in engine head to remove any thread sealant residue.
Clean any sealant residue from old sensor if the sensor is going to be reused.
1. If the sensor is being reused, apply thread sealant GM P/N 12345382 (Canadian P/N 10953489)
or equivalent, to sensor threads.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the ECT sensor.
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Tighten the sensor to 23 N.m (17 lb ft).
3. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then
pull back to confirm a positive engagement. 4. Install the fuel injector sight shield. 5. Fill the engine
cooling system to proper level. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling
(LNJ GE 47716 Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining
and Filling (LY7 GE 47716 Fill).
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 6781
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Information and Instructions > Page 6782
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 6793
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 6794
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Information and Instructions > Page 6795
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Information and Instructions > Page 6796
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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Crankshaft Position Sensor Replacement > Page 6799
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Crankshaft Position Sensor Replacement > Page 6800
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Level Sensor: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor
Replacement - Secondary
Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement - Secondary
Fuel Level Sensor Replacement - Secondary
Removal Procedure
Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced.
Obtain a NEW seal prior to beginning this service procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and the float electrical connector. 4. Release the retaining tabs and remove the level sensor by
sliding up.
Installation Procedure
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Replacement - Secondary > Page 6806
1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place. 2. Connect the fuel level sender unit and the float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Replacement - Secondary > Page 6807
Fuel Level Sensor: Service and Repair Primary Fuel Level Sensor Replacement
Primary Fuel Level Sensor Replacement
Removal Procedure
Important: NEW fuel tank module seals are necessary each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and secondary modules prior to beginning this service
procedure.
Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1
located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of
the fuel pump modules.
1. Remove the fuel tank. 2. Remove the fuel pump module. 3. Disconnect the fuel level sender unit
and float electrical connector from the underside of the top of the pump module. 4. Release the
retaining tabs (1, 2) and remove the level sensor by sliding up.
Installation Procedure
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Replacement - Secondary > Page 6808
1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender
cap snaps into place (1, 2). 2. Connect the fuel level sender unit and float electrical connector. 3.
Install the fuel pump module into the fuel tank. 4. Install the fuel tank.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Wheels/Vehicle Underbody Component Views
Rear Axle and Fuel Tank Components
Near The Rear Differential
1 - Rear Differential Clutch Control Module (MH6) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP)
Canister Vent Solenoid 4 - Fuel Sending Unit 5 - Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Diagrams
Component Connector End Views
Fuel Tank Pressure (FTP) Sensor
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Fuel Tank Pressure Sensor: Service and Repair
Fuel Tank Pressure Sensor Replacement
Removal Procedure
1. Remove the fuel tank.
2. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure
sensor.
3. Position 2 flat-bladed screwdrivers, one on each side of the sensor, near the vacuum port. 4.
Carefully use the screwdrivers to lift and release the sensor from the fuel pump module.
Installation Procedure
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1. Install the fuel tank pressure sensor to the fuel pump module assembly. Ensure that the sensor
grommet is fully seated to the pump module.
2. Connect the pump module electrical connector to the fuel tank pressure sensor. 3. Install the fuel
tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
Intake Air Temperature Sensor: Specifications
Temperature Versus Resistance
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Intake Air Temperature Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Intake Air Temperature Sensor: Diagrams
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
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Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
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1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Instructions > Page 6827
Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Instructions > Page 6828
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Instructions > Page 6829
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Instructions > Page 6833
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Instructions > Page 6910
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Instructions > Page 6911
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Instructions > Page 6912
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Instructions > Page 6913
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 6914
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Instructions > Page 6915
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 6916
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 6917
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 6918
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 6919
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Instructions > Page 6920
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Instructions > Page 6921
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
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Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
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Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
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4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
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2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
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Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
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Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Manifold Pressure/Vacuum Sensor: Diagrams
Component Connector End Views - Continued
Manifold Absolute Pressure (MAP) Sensor (LNJ)
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Manifold Pressure/Vacuum Sensor: Service and Repair
Manifold Absolute Pressure Sensor Replacement
Removal Procedure
1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
2. Remove the MAP sensor retaining bolt (3) and bracket (2). 3. Remove the MAP sensor (1) and
the MAP sensor port seal if it is still retained in the intake manifold.
Installation Procedure
1. Install the MAP sensor (1) to the intake manifold.
Notice: Refer to Fastener Notice.
2. Install the MAP sensor retaining bracket (2) and bolt (3).
Tighten the bolt to 10 N.m (89 lb in).
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3. Connect the MAP sensor electrical connector.
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Oil Pressure Sensor: Service and Repair
Engine Oil Pressure Sensor and/or Switch Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the oil pressure indicator switch electrical connector (2).
3. Remove the oil pressure indicator switch from the engine block.
Installation Procedure
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1. Apply sealer to the oil pressure indicator switch threads. Refer to Sealers, Adhesives, and
Lubricants (See: Engine, Cooling and
Exhaust/Engine/Specifications/Mechanical Specifications/Sealers, Adhesives, and Lubricants) for
the correct part number.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the oil pressure indicator switch.
Tighten the switch to 16 N.m (12 lb ft).
3. Connect the oil pressure indicator switch electrical connector (2). 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations
Oxygen Sensor: Locations
Powertrain Component Views
Exhaust Components (LNJ)
1 - Heated Oxygen Sensor (HO2S) 1 2 - Heated Oxygen Sensor (HO2S) 2
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Instructions
Oxygen Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Oxygen Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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Instructions > Page 6979
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Oxygen Sensor: Connector Views
Component Connector End Views
Heated Oxygen Sensor (HO2S) 1 (LNJ)
Heated Oxygen Sensor (HO2S) 2 (LNJ)
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice
Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice > Page 7051
Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Oxygen Sensor Notice > Page 7052
Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
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Oxygen Sensor Notice > Page 7053
Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Heated Oxygen and
Oxygen Sensor Notice > Page 7054
Oxygen Sensor: Service Precautions
Heated Oxygen and Oxygen Sensor Notice
Heated Oxygen and Oxygen Sensor Notice
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen
sensor (O2S). Removing the pigtail or the connector will affect sensor operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector
and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of
any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring,
connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air
reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor causing poor performance.
* Do not damage the sensor pigtail and harness wires in such a way that the wires inside are
exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
* Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize
the ground wired sensor may rely on this ground as the only ground contact to the sensor.
Removal of the ground wire will cause poor engine performance.
* Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion. The engine harness may be repaired using Packard's
Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.
Silicon Contamination of Heated Oxygen Sensors Notice
Silicon Contamination of Heated Oxygen Sensors Notice
Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV
sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the
HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to
check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream
will have a white powdery coating. Silicon contamination causes a high but false HO2S signal
voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered
to the engine, causing a severe driveability problem. Eliminate the source of contamination before
replacing the oxygen sensor.
Excessive Force and Oxygen Sensor Notice
Excessive Force and Oxygen Sensor Notice
Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C
(120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe.
Heated Oxygen Sensor Resistance Learn Reset Notice
Heated Oxygen Sensor Resistance Learn Reset Notice
Notice: When replacing the HO2S perform the following:
* A code clear with a scan tool, regardless of whether or not a DTC is set
* HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S
failure.
Oxygen Sensor Notice
Oxygen Sensor Notice
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Oxygen Sensor Notice > Page 7055
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.
Heated Oxygen Sensor Wire Repair Notice
Heated Oxygen Sensor Wire Repair Notice
Notice: Do not solder heated oxygen sensor wires. Soldering the wires will result in the loss of the
air reference to the sensor. Refer to Engine Electrical for proper wire and connection repair
techniques.
Heated Oxygen Sensor Pigtail Notice
Heated Oxygen Sensor Pigtail Notice
Notice: The heated oxygen sensors each use a permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor. Damage or removal of the pigtail or the
connector affects proper operation of the heated oxygen sensor. Handle the oxygen sensor
carefully. Do not drop the oxygen sensor. Keep the in-line connector and the louvered end free of
grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the
wiring, the connector, or the terminals. Replace the oxygen sensor if the pigtail wiring, the
terminals, or the connector is damaged. Proper oxygen sensor operation requires an external air
reference. This external air reference is obtained by way of the oxygen sensor signal and heater
wires. Any attempt to repair the wires, the connectors, or the terminals results in the obstruction of
the air reference and degrades the oxygen sensor performance. A dropped oxygen sensor is a bad
oxygen sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor 1 Replacement
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 1 Replacement
Heated Oxygen Sensor 1 Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector from the heated oxygen sensor (HO2S). 3. Remove the HO2S from the
exhaust manifold.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
1. Apply a small amount of anti-seize compound to the threads of the HO2S.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S to the exhaust manifold.
Tighten the HO2S to 42 N.m (31 lb ft).
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3. Connect the engine wiring harness electrical connector to the HO2S. Push in the connector until
a click is heard and pull back to confirm a positive
engagement.
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Sensor 1 Replacement > Page 7059
Oxygen Sensor: Service and Repair Heated Oxygen Sensor 2 Replacement
Heated Oxygen Sensor 2 Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the HO2S 2 harness connector (3).
Important: Silicone based products will contaminate the HO2S. DO NOT use products containing
silicone on or near the HO2S.
3. Use a liquid penetrate before removing the sensor. 4. Remove the HO2S 2 (2) from the exhaust
pipe.
Installation Procedure
Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize
compound that does not contain silicone.
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1. Apply a small amount of anti-seize compound to the threads of the HO2S 2.
Notice: Refer to Component Fastener Tightening Notice.
2. Install the HO2S 2 (2).
Tighten the HO2S 2 to 42 N.m (31 lb ft).
3. Connect the HO2S 2 harness connector (3). Push in the connector until a click is heard, then pull
back to confirm a positive engagement. 4. Ensure the HO2S 2 harness pigtail connector is secure
to the chassis.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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and Instructions > Page 7065
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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and Instructions > Page 7066
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Automatic Transmission Electronic Component Views > Page 7167
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
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Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Automatic Transmission Electronic Component Views > Page 7168
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Automatic Transmission Electronic Component Views > Page 7169
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 7172
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 7173
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7178
Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 7179
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7180
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7181
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Component Information > Diagrams > Diagram Information and Instructions > Page 7182
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7183
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7184
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Component Information > Diagrams > Diagram Information and Instructions > Page 7185
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7186
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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Component Information > Diagrams > Diagram Information and Instructions > Page 7187
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7188
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7267
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7268
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7269
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7270
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7271
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7272
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7273
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7274
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7275
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
7280
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
7281
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
7282
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 7285
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 7286
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair
Catalyst Shield: Service and Repair
Catalytic Converter Heat Shield Replacement
Removal Procedure
1. Remove the muffler assembly. Refer to Muffler Replacement (LNJ) (See: Engine, Cooling and
Exhaust/Exhaust System/Muffler/Service and
Repair)Muffler Replacement (LY7) (See: Engine, Cooling and Exhaust/Exhaust
System/Muffler/Service and Repair) .
2. If the vehicle is equipped with all wheel drive (AWD) remove the propeller shaft underbody guard
loop bolts and guard loop.
Important: Support the fuel tank prior to removing the fuel tank strap bolt.
3. Remove the right fuel tank strap bolt, which also secures the rear of the catalytic converter heat
shield to the underbody.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst
Shield > Component Information > Service and Repair > Page 7292
Important: The heat shields at the dash panel and the catalytic converter overlap and utilizing
common rivet attachment points.
4. Drill out the rivets. 5. Remove the catalytic converter heat shield.
Installation Procedure
1. Position the catalytic converter heat shield, and insert the catalytic converter heat shield between
the underbody and the dash panel heat shield. 2. Install the NEW rivets.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Shield > Component Information > Service and Repair > Page 7293
Notice: Refer to Fastener Notice .
3. Install the fuel tank strap bolt.
Tighten the bolt to 25 N.m (18 lb ft).
4. If the vehicle is equipped with AWD, install the propeller shaft underbody guard loop and bolts.
Tighten the bolts to 25 N.m (18 lb ft).
5. Install the muffler assembly. Refer to Muffler Replacement (LNJ) (See: Engine, Cooling and
Exhaust/Exhaust System/Muffler/Service and Repair
)Muffler Replacement (LY7) (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service
and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Canister Purge Solenoid: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 7298
Canister Purge Solenoid: Diagrams
Component Connector End Views
Evaporative Emission (EVAP) Canister Purge Solenoid (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 7299
Canister Purge Solenoid: Service and Repair
Evaporative Emission Canister Purge Solenoid Valve Replacement
Removal Procedure
1. Turn OFF the ignition. 2. Disconnect the evaporative emission (EVAP) canister purge solenoid
valve electrical connector. 3. Disconnect the EVAP canister purge solenoid valve hose/pipe.
4. Remove the EVAP canister purge solenoid valve retaining bolt (2). 5. Remove the EVAP
canister purge solenoid valve (1) from the intake manifold.
Installation Procedure
1. Position the EVAP canister purge solenoid valve (1) on the intake manifold.
Notice: Refer to Fastener Notice.
2. install the EVAP canister purge solenoid valve bolt (2).
Tighten the EVAP canister purge valve retaining bolt to 10 N.m (89 lb in).
3. Connect the EVAP canister purge solenoid valve hose/pipe. 4. Connect the EVAP canister purge
solenoid valve electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service and Repair
Evaporative Canister Filter: Service and Repair
Evaporative Emission Canister Filter Replacement
Removal Procedure
Important: The evaporative emission (EVAP) canister filter cover must also be replaced when the
EVAP filter is replaced to ensure proper operation of the EVAP canister.
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the EVAP canister from the
vehicle.
3. Carefully release the canister filter cover rear retaining tabs. 4. Carefully release the canister
filter cover forward retaining tabs and remove the cover from the EVAP canister. 5. Discard the
EVAP canister filter cover.
6. Remove the filter from the canister and discard the filter. 7. Clean the inside of the EVAP
canister filter housing with a clean shop towel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service and Repair > Page 7303
1. Install a NEW filter to the canister filter housing.
Important: Ensure that the seal is properly seated in the NEW EVAP filter cover.
2. Install a NEW EVAP filter cover to the EVAP canister. 3. Install the EVAP canister to the vehicle.
4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations
Canister Vent Valve: Locations
Wheels/Vehicle Underbody Component Views
Rear Axle and Fuel Tank Components
Near The Rear Differential
1 - Rear Differential Clutch Control Module (MH6) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP)
Canister Vent Solenoid 4 - Fuel Sending Unit 5 - Fuel Tank Pressure (FTP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7308
Canister Vent Valve: Diagrams
Component Connector End Views
Evaporative Emissions (EVAP) Canister Vent Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7309
Canister Vent Valve: Service and Repair
Evaporative Emission Canister Vent Solenoid Valve Replacement
Removal Procedure
1. Remove the evaporative emission (EVAP) canister from the vehicle.
2. Rotate the EVAP canister vent valve counterclockwise to release from the locked position.
3. Remove the vent valve from the EVAP canister.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 7310
1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to
the released position.
2. Rotate vent valve clockwise to secure into the locked position. 3. Install the EVAP canister to the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine
Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine
Evaporative Emission Hoses/Pipes Replacement - Engine
Removal Procedure
1. Remove the nuts (1) securing the evaporative emission (EVAP) hose/pipe (2) to the strut tower.
2. Disconnect the EVAP purge hose/pipe (2) from the purge solenoid.
3. Disconnect the engine EVAP purge hose/pipe from the chassis EVAP purge hose/pipe. 4. Cap
or plug both the engine and chassis EVAP purge hose/pipes to prevent contamination.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine > Page 7315
5. Remove the EVAP hose/pipe (2) from the retainer (3). 6. Remove the EVAP hose/pipe (2) from
the vehicle.
Installation Procedure
1. Install the EVAP hose/pipe (2) to the vehicle. 2. Install the EVAP hose/pipe (2) to the retainer (3).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine > Page 7316
3. Remove the caps or plugs from both the engine and chassis EVAP purge hose/pipes. 4.
Connect the engine EVAP purge hose/pipe to the chassis EVAP purge hose/pipe.
5. Connect the EVAP purge hose/pipe (2) to the purge solenoid.
Notice: Refer to Fastener Notice.
6. Install the nuts (1) securing the evaporative emission EVAP hose/pipe (2) to the strut tower.
Tighten the nuts to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine > Page 7317
Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine/Chassis
Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis
Removal Procedure
Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or
EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the
negative battery cable, except for those tests where battery voltage is required.
Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening
must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.
Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with
the same type of line.
1. Disconnect the engine evaporative emission (EVAP) purge hose/pipe from the chassis EVAP
purge hose/pipe. 2. Cap or plug both the engine and chassis EVAP purge hose/pipes to prevent
contamination.
3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Disconnect the EVAP purge hose/pipe
from the EVAP canister. 5. Cap or plug both the EVAP purge hose/pipe and canister to prevent
contamination.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine > Page 7318
6. Release the pipe retainers (1) from the vehicle underbody. 7. Remove the purge pipe from the
pipe retainers. 8. Remove the purge pipe from the vehicle.
Installation Procedure
1. Position the purge pipe to the vehicle. 2. Install the purge pipe to the pipe retainers. 3. Secure
the pipe retainers (1) to the vehicle underbody.
4. Remove the caps or plugs from both the EVAP purge hose/pipe and canister. 5. Connect the
EVAP purge hose/pipe to the EVAP canister. 6. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes
Replacement - Engine > Page 7319
7. Remove the caps or plugs from both the engine and chassis EVAP purge hose/pipes. 8.
Connect the engine EVAP purge hose/pipe to the chassis EVAP purge hose/pipe.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Service and Repair
EGR Tube: Service and Repair
Exhaust Gas Recirculation Pipe Replacement
Removal Procedure
1. Remove the injector sight shield.
2. Remove the bolt (3) retaining the exhaust gas recirculation (EGR) pipe (4) to the EGR valve (1).
3. Remove the 2 bolts (5) securing the EGR pipe (4) to the exhaust manifold. 4. Remove the EGR
pipe (4). 5. Remove the EGR pipe to exhaust manifold gasket.
Installation Procedure
1. Install the EGR pipe to exhaust manifold gasket. 2. Install the EGR pipe (4).
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Service and Repair > Page 7324
3. Install the 2 bolts (5) that secure the EGR pipe (4) to exhaust manifold.
Tighten the bolts to 10 N.m (89 lb in).
4. Install the bolt (3) the secures the EGR pipe (4) bolt to the EGR valve (1).
Tighten the bolt to 30 N.m (22 lb ft).
5. Install the injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Diagrams
EGR Valve: Diagrams
Component Connector End Views
Exhaust Gas Recirculation (EGR) Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Diagrams > Page 7328
EGR Valve: Service and Repair
Exhaust Gas Recirculation Valve Replacement
Removal Procedure
1. Remove the exhaust gas recirculation (EGR) pipe (4). 2. Disconnect the EGR valve electrical
connector. 3. Remove the EGR valve bolts (2). 4. Remove the EGR valve (1). 5. Remove the EGR
valve gasket. 6. Clean the EGR valve mating surface.
Installation Procedure
1. Install the EGR valve (1) with a new gasket to the intake manifold.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Diagrams > Page 7329
2. Install the EGR valve bolts (2).
Tighten the bolts to 30 N.m (22 lb ft).
3. Connect the EGR valve electrical connector. 4. Install the EGR pipe (4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair
PCV Valve Hose: Service and Repair
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (See: Fuel
Delivery and Air Induction/Fuel Injector/Service
and Repair/Removal and Replacement/Fuel Injector Sight Shield Replacement) .
2. Disconnect the positive crankcase ventilation (PVC) fresh air pipe (1) from the air cleaner duct.
3. Disconnect the PVC fresh air pipe (1) from the valve cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 7334
4. Disconnect the PVC foul air pipe (1) from the intake manifold.
Installation Procedure
1. Connect the PVC foul air pipe (1) to the PVC valve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
PCV Valve Hose > Component Information > Service and Repair > Page 7335
2. Connect the PVC fresh air pipe (1) to the valve cover.
3. Connect the PVC fresh air pipe (1) to the air cleaner duct. 4. Install the fuel injector sight shield.
Refer to Fuel Injector Sight Shield Replacement (See: Fuel Delivery and Air Induction/Fuel
Injector/Service
and Repair/Removal and Replacement/Fuel Injector Sight Shield Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair
Positive Crankcase Ventilation Valve: Service and Repair
Positive Crankcase Ventilation Valve Replacement
Removal Procedure
Important: The PCV valve is not removable from the valve rocker arm cover. The PCV valve and
rocker arm cover must be replaced as an assembly.
1. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal - Left Side
(See: Engine, Cooling and
Exhaust/Engine/Service and Repair/Overhaul) .
2. Remove the screws (1) from the PCV baffle. 3. Remove the PCV baffle (2). 4. Clean the PCV
valve (3) or replace the valve cover (4).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Page 7339
1. Install the PCV baffle (2).
Notice: Refer to Fastener Notice .
2. Install the PCV baffle screws (1).
Tighten the screws to 6 N.m (53 lb in).
3. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Removal - Left Side
(See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Overhaul) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure.......................................................................................................................................
...............................................384-425 kPa (56-62 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Service Precautions > Technician Safety Information > Page 7346
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7349
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7350
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned
ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition
reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference
pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference
pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the
primary fuel tank module, eliminating the need for a return pipe from the engine. A returnless fuel
system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to
the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative
emissions.
An electric turbine style fuel pump attaches to the primary fuel tank module inside the fuel tank.
The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator,
and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint
that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of
the primary fuel tank module. The primary fuel tank module contains a reverse flow check valve.
The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the
fuel rail in order to prevent long cranking times.
The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel
pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet
pump and the secondary jet pump through a restrictive orifice located on the pump cover. The
primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates
a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through
the fuel transfer pipe, to the primary side of the fuel tank.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
*
Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 384-425 kPa (56-62 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7351
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 384-425 kPa
(56-62 psi).
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail.
3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan
tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF with
a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the primary fuel pump
module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the primary fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Replacement - Chassis
* Fuel Hose/Pipes Replacement - Engine Compartment
* Fuel Injector Replacement
* Primary Fuel Tank Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 7356
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 7357
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release >
System Information > Service and Repair > Procedures > Page 7358
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position
Sensor > Component Information > Locations > Page 7365
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Sensor > Component Information > Locations > Page 7366
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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Sensor > Component Information > Locations > Page 7367
1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air
Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair
Air Cleaner Fresh Air Duct/Hose: Service and Repair
Air Cleaner Inlet Duct Replacement
Removal Procedure
1. Loosen the clamps at both ends of the air cleaner intake duct. 2. Remove the positive crankcase
ventilation (PCV) fresh air pipe from the air cleaner intake duct. 3. Remove the air cleaner intake
duct from the mass air flow (MAF) sensor and throttle body.
Installation Procedure
1. Install the air cleaner intake duct to the MAF sensor and throttle body. 2. Install the PCV fresh air
pipe to the air cleaner intake duct.
Notice: Refer to Fastener Notice.
3. Tighten the clamps at both ends of the air cleaner intake duct.
Tighten the clamps to 4 N.m (35 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Air Cleaner Element Replacement
Removal Procedure
1. Remove the air cleaner intake duct.
2. Disconnect the mass air flow (MAF) sensor electrical connector.
3. Release the clamps (2) on the side of the air cleaner assembly. 4. Remove the air cleaner
assembly lid (1) by tilting to release the lid from the lower housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 7375
5. Remove the air cleaner element (2) from the lower housing (1).
Installation Procedure
1. Install the air cleaner element (2) into the lower housing (1).
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Element > Component Information > Service and Repair > Page 7376
2. Install the air cleaner assembly lid (1) by first engaging the hinge then lower the cover into the
closed position. 3. Fasten the clamps (2) on the side of the air cleaner assembly.
4. Connect the MAF sensor electrical connector. 5. Install the air cleaner intake duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7382
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7383
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7384
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7385
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7386
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7387
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7388
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7389
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7390
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7391
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Component Information > Diagrams > Diagram Information and Instructions > Page 7440
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7469
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7470
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7471
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7472
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7473
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7474
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7475
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7476
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7477
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 7478
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7479
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 7480
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 7481
Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 7482
1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y.
INFORMATION
Bulletin No.: 10-06-04-015
Date: December 08, 2010
Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles
Models:
2007-2011 GM Passenger Cars and Trucks
General Motors' position regarding the Environmental Protection Agency announcement allowing
the use of E 15 in 2007 and newer vehicles:
- General Motors' remains focused on securing a safe and positive driving experience for our
customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to
confusion for consumers as to what fuel their vehicle should use. In response, we will continue to
encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The
vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be
used in GM vehicles that do not have a flex fuel designation.
- GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and
these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15
percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However,
ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel
designation as they are not designed and certified to run on gasoline consisting of more than 10
percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual.
- We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce
petroleum dependence and the carbon footprint of driving. As the global leader in producing
vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for
the 2011 model year.
Disclaimer
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7487
Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada)
INFORMATION
Bulletin No.: 05-06-04-022G
Date: October 27, 2010
Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel
Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY
Models:
2011 and Prior GM Passenger Cars and Trucks (Canada Only)
Supercede: This bulletin is being revised to update the model years and include an additional
gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F
(Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate
Bulletin Number 04-06-04-047I.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those
vehicles that have experienced deposit related concerns may especially benefit from use of TOP
TIER Detergent Gasoline.
Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline
Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB
Top Tier Fuel Availability
Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first
national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada
began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began
offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent
Gasoline in May of 2010.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7488
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane
grades :
Chevron Canada (markets in British Columbia and western Alberta)
- Shell Canada (nationally)
- Petro-Canada (nationally)
- Sunoco-Canada (Ontario)
- Esso-Canada (nationally)
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no
metallic additives. It meets new, voluntary deposit control standards developed by six automotive
companies that exceed the detergent recommendations of Canadian standards and does not
contain metallic additives, which can damage vehicle emission control components.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have
already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not
all fuel marketers will offer this product. Once fuel marketers make public announcements, they will
appear on a list of brands that meet the TOP TIER standards.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW,
General Motors, Honda, Toyota, Volkswagen and Audi.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a
detergent additive. However, the requirement is minimal and in many cases, is not sufficient to
keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency
requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any
detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of
detergent is needed than what is required or recommended, and no metallic additives are allowed.
Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency and the intentional addition of metallic additives is an
issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal
fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP
TIER Detergent Gasoline will help reduce deposit related concerns.
Who should use TOP TIER Detergent Gasoline?
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have
experienced deposit related concerns may especially benefit from use of TOP TIER Detergent
Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website,
http://www.toptiergas.com/.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7489
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7490
Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information
INFORMATION
Bulletin No.: 04-06-04-047I
Date: August 17, 2009
Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance,
Stall Concerns) - U.S. Only
Models:
2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010
HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only)
Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier
Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F.
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by six automotive companies. All
vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest
Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related
concerns may especially benefit from the use of TOP TIER Detergent Gasoline.
Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline
Intake valve: - 10,000 miles with Legal Minimum additive
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent
Gasoline Standards:
- Chevron
- Chevron-Canada
- QuikTrip
- Conoco
Phillips 66
- 76
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7491
- Shell
- Shell-Canada
- Entec Stations located in the greater Montgomery, Alabama area.
- MFA Oil Company located throughout Missouri.
- Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa.
The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky.
Aloha Petroleum
- Tri-Par Oil Company
- Turkey Hill Minit Markets
- Texaco
- Petro-Canada
- Sunoco-Canada
- Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new,
voluntary deposit control standards developed by six automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program
and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements, they will appear
on a list of brands that meet the TOP TIER standards.
Where Can I find the Latest Information on TOP TIER Fuel and Retailers?
On the web, please visit www.toptiergas.com for additional information and updated retailer lists.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi,
BMW, General Motors, Honda, Toyota and Volkswagen.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
Why did the six automotive companies join together to develop TOP TIER?
All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining
together emphasized that low detergency is an issue of concern to several automotive companies.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7492
Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions
Bulletin No.: 05-06-04-035C
Date: July 30, 2007
INFORMATION
Subject: Usage of E85 Fuels in GM Vehicles
Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2
2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008
Saab 9-7X
Supercede:
This bulletin is being revised to add the 2008 model year and additional engines with E85
capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System).
Customer Interest in E85 Fuel
As the retail price of gasoline increases, some locations in the country are seeing price differentials
between regular gasoline and E85 where E85 is selling for substantially less than regular grade
gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in
non-E85 compatible vehicles.
Only vehicles designated for use with E85 should use E85 blended fuel.
E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15%
gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10%
ethanol.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
Using E85 Fuels in Non-Compatible Vehicles
General Motors is aware of an increased number of cases where customers have fueled
non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or
with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in
one or more of the following conditions:
Lean Driveability concerns such as hesitations, sags and/or possible stalling.
SES lights due to OBD codes.
Fuel Trim codes P0171 and/or P0174.
Misfire codes (P0300).
Various 02 sensor codes.
Disabled traction control or Stability System disabled messages.
Harsh/Firm transmission shifts.
Fuel system and/or engine mechanical component degradation.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been
fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J
44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with
gasoline - preferably one of the Top Tier brands.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. > Page 7493
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at
www.livegreengoyellow.com.
E85 Compatible Vehicles
The only E85 compatible vehicles produced by General Motors are shown.
Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or
www.livegreengoyellow.com are E85 compatible.
All other gasoline and diesel engines are NOT E85 compatible.
Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause
driveability issues, service engine soon indicators as well as increased fuel system corrosion.
Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms
of the New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Technical Service Bulletins > Page 7494
Fuel: Specifications
GASOLINE OCTANE
Use regular unleaded gasoline with a posted octane rating of 87 or higher. If the octane rating is
less than 87, you may notice an audible knocking noise when you drive, commonly referred to as
spark knock. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. If you
are using gasoline rated at 87 octane or higher and you hear heavy knocking, your engine needs
service.
GASOLINE SPECIFICATIONS
At a minimum, gasoline should meet ASTM specification D 4814 in the United States or
CAN/CGSB-3.5 in Canada. Some gasolines may contain an octane-enhancing additive called
methylcyclopentadienyl manganese tricarbonyl (MMT). General Motors recommends against the
use of gasolines containing MMT.
CALIFORNIA FUEL
If your vehicle is certified to meet California Emission Standards, it is designed to operate on fuels
that meet California specifications. See the underhood emission control label. If this fuel is not
available in states adopting California emissions standards, your vehicle will operate satisfactorily
on fuels meeting federal specifications, but emission control system performance may be affected.
The malfunction indicator lamp may turn on and your vehicle may fail a smog-check test. If it is
determined that the condition is caused by the type of fuel used, repairs may not be covered by
your warranty.
ADDITIVES
To provide cleaner air, all gasolines in the United States are now required to contain additives that
will help prevent engine and fuel system deposits from forming, allowing your emission control
system to work properly. In most cases, you should not have to add anything to your fuel. However,
some gasolines contain only the minimum amount of additive required to meet U.S. Environmental
Protection Agency regulations. To help keep fuel injectors and intake valves clean, or if your
vehicle experiences problems due to dirty injectors or valves, look for gasoline that is advertised as
TOP TIER Detergent Gasoline. Also, your dealer has additives that will help correct and prevent
most deposit-related problems.
Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be
available in your area. General Motors recommends that you use these gasolines if they comply
with the specifications described earlier. However, E85 (85% ethanol) and other fuels containing
more than 10% ethanol must not be used in vehicles that were not designed for those fuels.
NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in the fuel system and also damage plastic and rubber parts.
That damage would not be covered under your warranty.
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General Motors recommends against the use of such
gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the
emission control system may be affected. The malfunction indicator lamp may turn on. If this
occurs, return to your dealer for service.
NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber
parts. That damage would not be covered under your warranty.
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such
gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the
emission control system may be affected. The malfunction indicator lamp may turn on.
FUELS IN FOREIGN COUNTRIES
If you plan on driving in another country outside the United States or Canada, the proper fuel may
be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text
on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To
check the fuel availability, ask an auto club, or contact a major oil company that does business in
the country where you will be driving.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Gasoline/Gasoline Vapors Caution
Fuel: Service Precautions Gasoline/Gasoline Vapors Caution
Gasoline/Gasoline Vapors Caution
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Gasoline/Gasoline Vapors Caution > Page 7497
Fuel: Service Precautions Actions to Take When Working with Fuel Caution
Actions to Take When Working with Fuel Caution
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
* Use forced air ventilation such as a fan set outside of the trunk.
* Plug or cap any fuel system openings in order to reduce fuel vapor formation.
* Clean up any spilled fuel immediately.
* Avoid sparks and any source of ignition.
* Use signs to alert others in the work area that fuel system work is in process.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Page 7498
Fuel: Testing and Inspection
Alcohol/Contaminants-in-Fuel Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Test Description
Water contamination in the fuel system may cause driveability conditions such as hesitation,
stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector
at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system
is contaminated with water, inspect the fuel system components for rust or deterioration.
Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system
deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as
hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles
not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel
filter restriction.
Special Tool
J 44175 Fuel Composition Tester
System Verification
The fuel sample should be drawn from the bottom of the tank so that any water present in the tank
will be detected. The sample should be bright and clear.
If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the
bottom of the sample, perform the Particulate Contaminants in Fuel Testing Procedure. If alcohol
contamination is suspected, perform the Alcohol in Fuel Testing procedure.
Alcohol in Fuel Testing with Special Tool
1. Test the fuel composition using J 44175 and Instruction Manual. 2. If water appears in the fuel
sample, clean the fuel system. 3. Subtract 50 from the reading on the DMM in order to obtain the
percentage of alcohol in the fuel sample. 4. If the fuel sample contains more than 15 percent
ethanol, add fresh, regular gasoline to the vehicle fuel tank. 5. Test the fuel composition. 6. If
testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle.
Alcohol in Fuel Testing without Special Tool
1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder
with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid
volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15
seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper
and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for
approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the
fuel, the
volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml
(0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this
indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat
more because this procedure does not extract all of the alcohol from the fuel.
Particulate Contaminants in Fuel Testing Procedure
1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the
container on a level surface for approximately 5 minutes in order to allow settling of the particulate
contamination. Particulate
contamination will show up in various shapes and colors. Sand will typically be identified by a white
or light brown crystals. Rubber will appear as black and irregular particles.
3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel
system.
Repair Instructions
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information
> Service Precautions > Page 7499
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel System Cleaning
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures
Fuel Pressure Release: Procedures
Fuel Pressure Relief (With CH 48027)
Fuel Pressure Relief (With CH 48027)
Special Tools
CH-48027 Digital Pressure Gage
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views.
2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 4. Remove the fuel rail service port cap.
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel
rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the
CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in
order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the
approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 7505
* The areas surrounding the connections
Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is
NOT necessary to proceed with the following steps.
Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from
around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail
service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap.
Fuel Pressure Relief (Without CH 48027)
Fuel Pressure Relief (Without CH 48027)
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to
Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank
vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress
(open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port,
and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the
engine cover, if required. 9. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 7506
Fuel Pressure Release: Removal and Replacement
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > Procedures > Page 7507
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's
Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 7516
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 7517
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 7518
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Injector: > 03-06-04-030G > Apr > 09 > Fuel System Driveability Issues/MIL/Multiple DTC's > Page 7519
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's
Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's
TECHNICAL
Bulletin No.: 03-06-04-030G
Date: April 22, 2009
Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171,
P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT
CH-47976)
Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors
Attention:
GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines
other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should
have those injectors replaced.
Supercede: This bulletin is being revised to update the model year to 2009 and to provide
applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section
06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various driveability symptoms:
- Extended Crank Time
- Hard to Start
- MIL/SES Illuminated with DTCs
- Hesitation
- Lack of Power
- Surge or Chuggle
- Rough Idle
- Light or Intermittent Misfire
Cause
Due to various factors, the fuel injectors may become restricted. Extensive testing has
demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific
fuel, fuel constituent, or engine condition has been identified as causing the restriction. The
restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to
illuminate or the engine to develop various driveability symptoms.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7525
Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure.
Under NO circumstances should this procedure be modified, changed or shortened. As a long term
solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent
Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to
the following Corporate Bulletin Numbers:
- 04-06-04-047G (U.S. Only)
- 05-06-04-022D (Canada ONLY)
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
approved for use with General Motors fuel system components. Other injector cleaners may cause
damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory
testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with
General Motors fuel system components, as long as the cleaning procedure is followed correctly.
Injector Cleaning Procedure
The following tools, or their equivalent, are required:
- CH-47976 Active Fuel Injector Tester (AFIT)
- J 35800-A Fuel Injector Cleaner
- J 37287 Fuel Line Shut-off Adapter
- J 42964 Fuel Line Shut-off Adapter
- J 42873 Fuel Line Shut-off Adapter
- * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N
88861804)
- * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012)
Active Fuel Injector Tester (AFIT- CH-47976)
Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact
to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel
Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI.
Important
As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be
tested with the AFIT. Depending on the model, it may be possible to enter the previous model year
and proceed with testing using the DLC connection. If this is not possible on the model that you are
working on, it will be necessary to use the direct connection method outlined in the AFIT User
Guide (See Pages 17-31).
General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel
injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector
Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide.
The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more
precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the
AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel
injector concern).
The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and
fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current
counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing
the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions.
Training (U.S.)
To access the training video on AFIT, take the following path at the GM Training Website:
1. After logging into the training website, choose the link on the left side of the page titled "web
video library."
2. Then choose "technical."
3. Next, within the search box, type in September course number "10206.09D.
4. This will bring up a link with this course. Scroll through to choose "feature topic."
5. At this point, the seminar can be chosen to view or the video related to the AFIT.
Additional training is available from the training website. Please see TECHassist 16044.18T2
Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more
information on GM Upper Engine and Fuel Injector Cleaner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7526
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Training (Canada)
To access the training video on AFIT, take the following path at the GMPro LMS Training Website:
1. After logging into the website, choose the link on the left side of the page titled "Catalog."
2. Then choose "Catalog Search."
3. Next, within the search box, Select Course Number - Contains - "T" then select search.
4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector
Tester" and select "View."
5. At this point, a new window will open and the program can be Launched.
Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE).
Techlink
Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel
Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following
path:
1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada).
2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service
Library of GM GlobalConnect).
3. Click on the GM Techlink Hyperlink.
4. Click on the Archives Hyperlink at GM Techlink.
- Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the
June 2006 Techlink Article.
- Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link
in the November 2006 Techlink Article.
Injector Cleaning Procedure
Notice
GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent
recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN
METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances
should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank.
Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that
exceeding the recommended cleaning solution concentration does not improve the effectiveness of
this procedure.
Important
Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned.
These vehicles should have any out of specification injectors replaced.
1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner container into the J
35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are
using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14
oz) of regular unleaded gasoline.
2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any
other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector
Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be
repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
3. Be sure to follow all additional instructions provided with the tool.
4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump
relay and disconnecting the oil pressure switch
connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7527
5. Turn the ignition to the OFF position.
6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel
feed and return lines coming off the fuel rail with J
37287, J 42873 or J 42964 as appropriate for the fuel system.
7. Connect the J 35800-A to the vehicle fuel rail.
8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
11. Disconnect the J 35800-A from the fuel rail.
12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines.
14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is
flushed from the fuel rail and fuel lines.
15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N
88861012]) into the tank and advise the customer to
fill the tank.
16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend
that they add a bottle of GM Fuel System Treatment
Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should
keep the customer from having to repeat the injector cleaning procedure.
17. Road test the vehicle to verify that the customer concern has been corrected.
Parts Information
* Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder
engines.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 03-06-04-030G > Apr > 09 >
Fuel System - Driveability Issues/MIL/Multiple DTC's > Page 7528
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Fuel Injector Resistance.......................................................................................................................
..................................................................11-14 ohms
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 7531
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Pressure Drop......................................................................................................................................
................................................................20 kPa (5 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions
Fuel Injector: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7534
Fuel Injector: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7535
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7536
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 7537
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 7538
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7616
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7617
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7618
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7619
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7620
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7621
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7622
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7623
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7624
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7625
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7626
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7627
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7628
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7629
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7630
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7631
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7632
Fuel Injector: Connector Views
Component Connector End Views
Fuel Injector 1 (LNJ)
Fuel Injector 2 (LNJ)
Fuel Injector 3 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7633
Fuel Injector 4 (LNJ)
Fuel Injector 5 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Diagram Information and Instructions > Page 7634
Fuel Injector 6 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service Precautions > Technician Safety Information
Fuel Injector: Technician Safety Information
Lower O-Ring Removal Caution
Caution: Verify that the lower (small) O-ring of each injector does not remain in the lower manifold
in order to reduce the risk of fire and personal injury.
If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat
properly in the injector socket. Improper seating could cause a fuel leak.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service Precautions > Technician Safety Information > Page 7637
Fuel Injector: Vehicle Damage Warnings
Fuel Injector Balance Test Notice
Notice: Do Not repeat any portion of this test before running the engine in order to prevent the
engine from flooding.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J 39021 or Tech 2)
Fuel Injector Diagnosis (w/J39021 or Tech 2)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. The
ignition voltage is supplied directly to the fuel injectors. The ECM controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump
relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise
amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the
system fuel pressure that can be recorded and used to compare each injector.
Diagnostic Aids
* Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that
is causing the condition.
* Operating the vehicle over a wide temperature range may help isolate the fuel injector that is
causing the condition.
* Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector
condition may only be apparent at a certain temperature, or under certain conditions.
Special Tools Required
* CH-48027 Digital Pressure Gage
* J 39021-410 Fuel Injector Harness Adapter
* J 39021 Fuel Injector Coil and Balance Tester
* J 39021-210 Injector Tester Adapter Box
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
^ If the injectors measure OK, perform the Fuel Injector Balance Test Fuel Pressure Test.
^ If not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
^ If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test Fuel Pressure
Test for further diagnosis of the fuel injectors.
^ If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total
resistance value. Divide the total resistance value by the number of fuel injectors to obtain an
average resistance value. Subtract the lowest individual fuel injector resistance value from the
average resistance value. Compute the difference between the highest individual fuel injector
resistance value and the average resistance value. Replace the fuel injector that displays the
greatest difference above or below the average.
Important:
* DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F).
Irregular fuel pressure readings may result due to hot soak fuel boiling.
* Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 7640
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
Fuel Injector Balance Test-Fuel Pressure Test
1. Install a fuel pressure gage. 2. Turn ON the ignition, with the engine OFF.
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Command the fuel pump relay ON with a scan tool.
3. Observe the fuel pressure gage with the fuel pump commanded ON. The fuel pressure should
be 384-425 kPa (56-62 psi).
^ If the fuel pressure is not 384-425 kPa (56-62 psi), refer to Fuel System Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
4. Monitor the fuel pressure gage for one minute. The fuel pressure should not decrease more than
34 kPa (5 psi).
^ If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
5. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with
Tech 2.
Fuel Injector Balance Test with Special Tool
1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5
amp position. 2. Disconnect the multi-way harness connector of the fuel injectors. 3. Connect the J
39021, the J 39021-210, and the J 39021-410 to the fuel injector multi-way connector. 4. Command
the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the
fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
5. Command the fuel pump relay ON one more time and energize the fuel injector by depressing
the Push to Start Test button on the J 39021 at the
previously selected pressure.
6. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
7. Clear the Min/Max results. 8. Select Normal from the Display Mode. 9. Repeat steps 5 through 8
for each fuel injector.
10. Perform the Pressure Drop Calculation.
Fuel Injector Balance Test with Tech 2
Important: Vehicles with thief immobilizer disable the test.
1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last
command, as the fuel pressure begins to slowly degrade
and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record
this fuel pressure. This is the starting pressure at which you will pulse each injector.
2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions
menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the
fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected
pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027
and record the Min pressure.
Important: New test results will not be recorded if the Min/Max results are not cleared after each
injector is tested.
7. Clear the Min/Max results on the CH-48027. 8. Select Normal from the Display Mode on the
CH-48027. 9. Press Enter on the scan tool to bring you back to the Select Injector screen.
10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation.
Pressure Drop Calculation
1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the
pressure drop value.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 7641
2. Obtain a pressure drop value for each fuel injector. 3. Add all of the individual pressure drop
values except for the injector suspected of being faulty. This is the total pressure drop. 4. Divide the
total pressure drop by the number of fuel injectors that were added together. This is the average
pressure drop. The difference between
any individual pressure drop and the average pressure drop should not be more than 20 kPa (3
psi).
^ If the difference between any individual pressure drop and the average pressure drop is more
than 20 kPa (3 psi), replace the fuel injector.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel Injector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 7642
Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (With CH 47976)
Fuel Injector Diagnosis (w/CH47976)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the appropriate fuel injector pulse for each cylinder. The
ignition voltage is supplied directly to the fuel injectors. The ECM controls each fuel injector by
grounding the control circuit via a solid state device called a driver. A fuel injector coil winding
resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit
DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the
fuel injector increases.
The Active Fuel Injector Tester (AFIT), CH 47976, is used to test the fuel pump, fuel system leak
down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts
or selections, will indicate the steps required to perform each of the available tests. The tester will
perform all of the tests automatically and display results of the test. The results can also be down
loaded for storage and printing.
Special Tools Required
CH-47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Test
Verify the resistance of each fuel injector with one of the following methods:
* If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of
each fuel injector should be 11-14 ohms.
^ If the injectors measure OK, perform the AFIT Test Procedure.
^ If not within the specified range, replace the fuel injector.
* If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each
fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value.
The difference between the lowest value and the highest value should be equal to or less than 3
ohms.
^ If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure.
^ If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total
resistance value. Divide the total resistance value by the number of fuel injectors to obtain an
average resistance value. Subtract the lowest individual fuel injector resistance value from the
average resistance value. Compute the difference between the highest individual fuel injector
resistance value and the average resistance value. Replace the fuel injector that displays the
greatest difference above or below the average.
Important: DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C
(201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling.
Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
AFIT Test Procedure
1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. 4. Turn ON the AFIT and
select the vehicle. 5. Turn ON the ignition and perform the Injector Test.
^ If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis.
See: Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
6. View the test results.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Testing and Inspection > Fuel Injector Diagnosis (w/J 39021 or Tech 2) > Page 7643
^ If any injector exceeds the recommended tolerance, replace the injector(s).
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
Fuel Injector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures
Fuel Injector: Procedures
Fuel Injector Cleaning
Tools Required
* J 37287 Fuel Line Shut-Off Adapters
* J 35800-A Fuel Injector Cleaner
* J 42873-1 3/8 Fuel Line Shut-Off Valve
* J 42873-2 5/16 Return Pipe Shut-Off Valve
* J 42964-1 3/8 Fuel Pipe Shut-Off Valve
* J 42964-2 5/16 Fuel Pipe Shut-Off Valve
Notice:
* GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended.
DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN
DAMAGE FUEL SYSTEM COMPONENTS.
* Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the
vehicle fuel tank, as it may damage the fuel pump and other system components.
* Do not exceed the recommended cleaning solution concentration. Higher concentrations may
damage fuel system components. Testing has demonstrated that exceeding the recommended
cleaning solution concentration does not improve the effectiveness of this procedure.
Important: Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors
cleaned. These vehicles should have the injectors replaced.
1. Obtain J 35800-A (2).
Important: Make sure the valve at the bottom of the canister (3) is closed.
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper
Engine and Fuel Injector Cleaner twin reservoir
container into the J 35800-A, injector cleaning tank, then add 420 ml (14 oz) of regular unleaded
gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of
GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded
gasoline.
3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and
Fuel Injector Cleaner twin reservoir container into
the J 35800-A, injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you
are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper
Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This
procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml
total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of
gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional
instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel
pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel
feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped,
coming off the fuel rail with J
37287, or J 42964-1 , and J 42964-2 or J 42873-1, and J 42873-2 as appropriate for the fuel
system.
7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi).
9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20
minutes.
10. Turn the ignition to the OFF position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 7646
11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above
procedure should be done.
When the injector restriction returns to zero, proceed to step 12.
12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil
pressure switch connector, if equipped. 14. Remove the J 37287, or J 42964-1 and J 42964-2, or J
42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the
vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail
and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011
(Canadian P/N 88861012) into a nearly empty tank and advise the
customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel
System Treatment Plus to the fuel tank at every oil
change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to
repeat the injector cleaning procedure.
18. Road test the vehicle to verify that the customer concern has been corrected.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 7647
Fuel Injector: Removal and Replacement
Fuel Injector Sight Shield Replacement
Fuel Injector Sight Shield Replacement
Removal Procedure
1. Remove the oil cap (1) and the oil filler tube (2). 2. Disconnect the exhaust gas recirculation
(EGR) electrical connector (3).
3. Remove the injector sight shield from the studs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 7648
4. If replacing the sight shield studs, remove the studs from the intake manifold.
Installation Procedure
Notice: Refer to Fastener Notice .
1. If the injector sight shield studs were removed, install the studs to the intake manifold.
Tighten the studs to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 7649
2. Install the injector sight shield to the studs.
3. Connect the EGR electrical connector (3). 4. Install the oil filler tube (2) and the oil cap (1).
Fuel Injector Replacement
Fuel Injector Replacement
Removal Procedure
Notice: Use care in removing the fuel injectors in order to prevent damage to the fuel injector
electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of
cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
Important: If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service and Repair > Procedures > Page 7650
1. Remove the fuel rail.
2. Remove the fuel injector retaining clip (1). 3. Remove the fuel injector (3) from the fuel rail. 4.
Remove the fuel injector upper O-ring (2). 5. Remove the fuel injector lower O-ring (4).
Installation Procedure
1. Install the fuel injector upper O-ring (2). 2. Install the fuel injector lower O-ring (4). 3. Lubricate
the fuel injector upper O-ring (2) using GM P/N 12345616 (Canadian P/N 993182). 4. Install the
fuel injector (3) to the fuel rail. 5. Install the fuel injector retaining clip (1). 6. Install the fuel rail.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service
Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service
Metal Collar Quick Connect Fitting Service
Tools Required
J 37088-A Fuel Line Disconnect Tool Set
Removal Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel
Pressure Relief (Without CH 48027) Fuel Pressure
Relief (With CH 48027).
2. Remove the retainer from the quick-connect fitting.
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice.
Caution: Refer to Safety Glasses Caution.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the
female connector, then push inward in order to release
the locking tabs.
Caution: Refer to Relieving Fuel Pressure Caution.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 7655
5. Pull the connection apart. 6. Use a clean shop towel in order to wipe off the male pipe end. 7.
Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
Installation Procedure
Caution: Refer to Fuel Pipe Fitting Caution.
1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 7656
Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service
Plastic Collar Quick Connect Fitting Service
Removal Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Important: There are several types of plastic collar fuel and evaporative emission quick connect
fittings used on this vehicle.
* Bartholomew (1)
* Q Release (2)
* Squeeze to Release (3)
* Sliding Retainer (4)
The following instructions apply to all of these types of plastic collar quick connect fittings except
where indicated.
1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel
Pressure Relief (Without CH 48027) Fuel Pressure
Relief (With CH 48027).
Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice.
Caution: Refer to Safety Glasses Caution.
2. Using compressed air, blow any dirt out of the quick-connect fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 7657
3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect
fitting release tabs.
4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab
toward the other side of the slot in the fitting.
5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by
arrows on both sides of the plastic ring surrounding
the quick connect fitting.
6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on
one side of the release tab causing it to push in
slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only
move in one direction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler >
Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 7658
Caution: Refer to Relieving Fuel Pressure Caution.
7. Pull the connection apart.
Installation Procedure
Caution: Refer to Fuel Pipe Fitting Caution.
1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to
snap into place.
3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the
connection is secure.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel Pressure.......................................................................................................................................
...............................................384-425 kPa (56-62 psi)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information
Fuel Pressure: Technician Safety Information
Relieving Fuel Pressure Caution
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Service Precautions > Technician Safety Information > Page 7665
Fuel Pressure: Vehicle Damage Warnings
Fuel Pressure Notice
Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel
pressure regulator or the fuel pressure gage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal
Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal
Fuel Pressure Gage Installation and Removal
Tools Required
CH-48027 Digital Pressure Gage
Installation Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a
small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with a
shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an
approved container when the disconnection is complete.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3.
Remove the shop towel from around the fuel rail service port, and place in an approved gasoline
container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the
CH-48027, refer to the manufacture's directions.
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7668
1. Relieve the fuel system pressure, if required. Perform the following steps:
Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the
fuel pressure gage. Place the towel in an approved container when the connection of the fuel
pressure gage is complete.
1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into
an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel
from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the
CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the
fuel rail service port, and place in an approved gasoline container.
Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
* The fuel pipe connections
* The hose connections
* The areas surrounding the connections
Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from
the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if
required. 6. Tighten the fuel fill cap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7669
Fuel Pressure: Testing and Inspection Fuel System Diagnosis
Fuel System Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned
ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition
reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference
pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference
pulses cease to be detected and the ignition remains ON.
The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the
primary fuel tank module, eliminating the need for a return pipe from the engine. A returnless fuel
system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to
the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative
emissions.
An electric turbine style fuel pump attaches to the primary fuel tank module inside the fuel tank.
The fuel pump supplies high pressure fuel through the fuel filter, past the fuel pressure regulator,
and through the fuel feed pipe to the fuel injection system. The fuel pressure regulator has a T-joint
that diverts the needed fuel to the fuel rail with the unused fuel dropping back into the reservoir of
the primary fuel tank module. The primary fuel tank module contains a reverse flow check valve.
The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the
fuel rail in order to prevent long cranking times.
The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel
pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet
pump and the secondary jet pump through a restrictive orifice located on the pump cover. The
primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates
a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through
the fuel transfer pipe, to the primary side of the fuel tank.
Special Tools
* CH-48027 Digital Pressure Gage
* J 37287 Fuel Line Shut-off Adapter
Circuit/System Verification
Important:
* Inspect the fuel system for damage or external leaks before proceeding.
*
Verify that adequate fuel is in the fuel tank before proceeding.
* The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and
Instructions.
1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear
the fuel pump turn ON and OFF.
^ If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics
2. Ignition OFF, all accessories OFF, install a CH-48027. 3. Ignition ON, engine OFF, command the
fuel pump relay ON with a scan tool. Verify the fuel pressure is between 384-425 kPa (56-62 psi)
and
does not decrease more than 34 kPa (5 psi) in 1 minute.
Circuit/System Testing
Important: *
The fuel pump relay may need to be commanded ON a few times in order to obtain the highest
possible fuel pressure.
* DO NOT start the engine.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 7670
Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel
pressure gage while the fuel pump is operating. Verify the fuel pressure is between 384-425 kPa
(56-62 psi).
^ If the fuel pressure is greater than the specified range, replace the fuel pump module.
^ If the fuel pressure is less than the specified range, test, inspect, and repair the items listed
below. If all items test normal, replace the fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute.
^ If the fuel pressure decreases more than the specified value, perform the following procedure:
1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail.
3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan
tool and bleed the air from the CH-48027. 5. Command the fuel pump relay ON and then OFF with
a scan tool. 6. Close the valve on the J 37287. 7. Monitor the fuel pressure for 1 minute.
^ If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and
replace the leaking fuel injector(s).
^ If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace
the fuel pump module.
2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease
more than 14 kPa (2 psi) in 5 minutes.
^ If the fuel pressure decreases more than the specified value, replace the primary fuel pump
module.
3. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel
pressure with the CH-48027. The fuel pressure
should not drop off during acceleration, cruise or hard cornering.
^ If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test
normal, replace the primary fuel pump module.
* Restricted fuel feed pipe
* Restricted or plugged strainer
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections
4. If the fuel system tests normal, refer to Symptoms - Computers and Control Systems. See:
Computers and Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/Verification Tests and Procedures
* Fuel Hose/Pipes Replacement - Chassis
* Fuel Hose/Pipes Replacement - Engine Compartment
* Fuel Injector Replacement
* Primary Fuel Tank Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions
Fuel Pump Relay: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7676
Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7677
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7678
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7679
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7680
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7681
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7682
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7683
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7684
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7761
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7762
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7763
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7764
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7765
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7766
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7767
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7768
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7769
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7770
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7771
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7772
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> Component Information > Diagrams > Diagram Information and Instructions > Page 7773
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Service Precautions > Customer Safety Information
Fuel Rail: Customer Safety Information
Fuel Rail Stop Bracket Installation Caution
Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket
serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail
stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed
possibly causing a fire and personal injury from burns.
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Information > Service Precautions > Customer Safety Information > Page 7778
Fuel Rail: Vehicle Damage Warnings
Fuel Rail Notice
Notice:
* Use care when servicing the fuel system components, especially the fuel injector electrical
connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the
fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail
components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail
assembly.
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Information > Service Precautions > Page 7779
Fuel Rail: Service and Repair
Fuel Injection Fuel Rail Assembly Replacement
Removal Procedure
Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak,
always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are
different colors (black and brown), be sure to install the black O-ring in the upper position and the
brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made
of different materials.
Important: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and
other contaminants from entering the fuel passages. It is recommended that the fittings be capped,
and the holes be plugged during servicing.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Remove the upper intake manifold.
3. Disconnect the engine fuel feed pipe (1) at the fuel rail (4). 4. Disconnect the main fuel injector
harness electrical connector. 5. Disconnect the coolant temperature sensor and camshaft position
sensor electrical connectors 6. Disconnect the electrical connectors from the fuel injectors.
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Information > Service Precautions > Page 7780
7. Remove the fuel rail retaining bolts (2). 8. Remove the fuel rail assembly (1). 9. Remove the
injector O-ring seal from the spray tip end of each injector.
10. If removing the fuel injectors from the fuel rail is necessary. Refer to Fuel Injector Replacement.
Installation Procedure
Notice:
* Use care when servicing the fuel system components, especially the fuel injector electrical
connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the
fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail
components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail
assembly.
1. If the fuel injectors were removed from the fuel rail. Refer to Fuel Injector Replacement.
2. Lubricate the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182). 3. Install
the fuel injector nozzles into the lower intake manifold injector bores. 4. Press on the fuel rail (1)
using the palms of both hands until the fuel injectors are fully seated.
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Information > Service Precautions > Page 7781
Notice: Refer to Fastener Notice.
5. Install the fuel rail attaching bolts (2).
Tighten the bolt to 10 N.m (89 lb in).
6. Install the injector electrical harness to the fuel rail. 7. Apply lubricant to the fuel injector electrical
connectors. GM P/N 12377900, (Canadian P/N 10953529). 8. Connect the fuel injector electrical
connectors. 9. Connect the coolant temperature sensor and camshaft position sensor electrical
connectors
10. Connect the main fuel injector electrical harness connector.
11. Connect the fuel feed pipe (1) at the fuel rail (4). 12. Install the upper intake manifold. 13.
Connect the negative battery cable. 14. Inspect for fuel leaks.
1. Turn ON the ignition for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the
ignition. 4. Inspect for fuel leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis
Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure
Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or
EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the
negative battery cable, except for those tests where battery voltage is required.
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening
must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.
Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with
the same type of line.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Disconnect the negative battery terminal.
3. Disconnect the engine compartment fuel hose/pipe (2) from the chassis fuel hose/pipe (3). 4.
Cap the fuel hose/pipes to prevent contamination and fuel leakage. 5. Raise the vehicle. Refer to
Vehicle Lifting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7786
6. Disconnect the chassis fuel hose/pipe (2) from the fuel tank. 7. Cap the fuel hose/pipes to
prevent contamination and fuel leakage.
8. Release the pipe retainers (1) from the vehicle underbody. 9. Remove the fuel hose/pipe from
the pipe retainers.
10. Remove the fuel hose/pipe from the vehicle.
Installation Procedure
1. Install the fuel hose/pipe to the vehicle. 2. Install the fuel hose/pipe from the pipe retainers. 3.
Attach the pipe retainers (1) to the vehicle underbody. 4. Remove the caps from the fuel pipes.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7787
5. Connect the chassis fuel hose/pipe (2) to the fuel tank. 6. Lower the vehicle from the hoist. 7.
Remove the caps from the fuel pipes.
8. Connect the engine compartment fuel hose/pipe (2) to the chassis fuel hose/pipe (3). 9. Connect
the negative battery terminal.
10. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat cycling twice. 2.
Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. 3. If the
engine does not start, repeat steps.
11. Run the engine and check the system for leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7788
Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment
Fuel Hose/Pipes Replacement - Engine Compartment
Removal Procedure
Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a
damaged engine fuel feed pipe or the engine fuel return pipe.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Remove the exhaust crossover pipe. 3. Remove the 2 nuts
securing the fuel hose/pipe to the engine and transaxle. 4. Remove the fuel hose/pipe retainers
from the threaded studs on the engine and transaxle. 5. Clean all engine fuel pipe connections and
areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe
connections to avoid possible contamination of the fuel system.
6. Disconnect the engine compartment fuel hose/pipe (2) from the chassis fuel hose/pipe (3). 7.
Cap the fuel hose/pipes to prevent contamination and fuel leakage.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7789
8. Disconnect the engine compartment fuel hose/pipe (1) from the fuel rail (4). 9. Cap the fuel
hose/pipes to prevent contamination and fuel leakage.
10. Remove the fuel hose/pipe from the fuel pipe retainer (2).
Installation Procedure
1. Position the fuel hose/pipe to the engine. 2. Install the fuel hose/pipe retainers to the threaded
studs on the engine and transaxle.
Notice: Refer to Fastener Notice.
3. Install the 2 nuts securing the fuel hose/pipe to the engine and transaxle.
Tighten the nuts to 28 N.m (21 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7790
4. Install the fuel hose/pipe to the fuel pipe retainer (2). 5. Remove the caps from the fuel pipes. 6.
Connect the engine compartment fuel hose/pipe (1) to the fuel rail (4).
7. Remove the caps from the fuel pipes. 8. Connect the engine compartment fuel hose/pipe (2) to
the chassis fuel hose/pipe (3). 9. Install the exhaust crossover pipe.
10. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. 2. Repeat step 7.1 twice. 3.
Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. 4. If the
engine does not start, repeat steps 7.1-7.4.
11. Run the engine and check for fuel system leaks. 12. Install the fuel injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis
Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis
Fuel Hose/Pipes Replacement - Chassis
Removal Procedure
Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or
EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the
negative battery cable, except for those tests where battery voltage is required.
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening
must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.
Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with
the same type of line.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Disconnect the negative battery terminal.
3. Disconnect the engine compartment fuel hose/pipe (2) from the chassis fuel hose/pipe (3). 4.
Cap the fuel hose/pipes to prevent contamination and fuel leakage. 5. Raise the vehicle. Refer to
Vehicle Lifting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7795
6. Disconnect the chassis fuel hose/pipe (2) from the fuel tank. 7. Cap the fuel hose/pipes to
prevent contamination and fuel leakage.
8. Release the pipe retainers (1) from the vehicle underbody. 9. Remove the fuel hose/pipe from
the pipe retainers.
10. Remove the fuel hose/pipe from the vehicle.
Installation Procedure
1. Install the fuel hose/pipe to the vehicle. 2. Install the fuel hose/pipe from the pipe retainers. 3.
Attach the pipe retainers (1) to the vehicle underbody. 4. Remove the caps from the fuel pipes.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7796
5. Connect the chassis fuel hose/pipe (2) to the fuel tank. 6. Lower the vehicle from the hoist. 7.
Remove the caps from the fuel pipes.
8. Connect the engine compartment fuel hose/pipe (2) to the chassis fuel hose/pipe (3). 9. Connect
the negative battery terminal.
10. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat cycling twice. 2.
Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. 3. If the
engine does not start, repeat steps.
11. Run the engine and check the system for leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7797
Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment
Fuel Hose/Pipes Replacement - Engine Compartment
Removal Procedure
Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a
damaged engine fuel feed pipe or the engine fuel return pipe.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel
Pressure Relief (With CH 48027). 2. Remove the exhaust crossover pipe. 3. Remove the 2 nuts
securing the fuel hose/pipe to the engine and transaxle. 4. Remove the fuel hose/pipe retainers
from the threaded studs on the engine and transaxle. 5. Clean all engine fuel pipe connections and
areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe
connections to avoid possible contamination of the fuel system.
6. Disconnect the engine compartment fuel hose/pipe (2) from the chassis fuel hose/pipe (3). 7.
Cap the fuel hose/pipes to prevent contamination and fuel leakage.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7798
8. Disconnect the engine compartment fuel hose/pipe (1) from the fuel rail (4). 9. Cap the fuel
hose/pipes to prevent contamination and fuel leakage.
10. Remove the fuel hose/pipe from the fuel pipe retainer (2).
Installation Procedure
1. Position the fuel hose/pipe to the engine. 2. Install the fuel hose/pipe retainers to the threaded
studs on the engine and transaxle.
Notice: Refer to Fastener Notice.
3. Install the 2 nuts securing the fuel hose/pipe to the engine and transaxle.
Tighten the nuts to 28 N.m (21 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Fuel Hose/Pipes Replacement - Chassis > Page 7799
4. Install the fuel hose/pipe to the fuel pipe retainer (2). 5. Remove the caps from the fuel pipes. 6.
Connect the engine compartment fuel hose/pipe (1) to the fuel rail (4).
7. Remove the caps from the fuel pipes. 8. Connect the engine compartment fuel hose/pipe (2) to
the chassis fuel hose/pipe (3). 9. Install the exhaust crossover pipe.
10. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. 2. Repeat step 7.1 twice. 3.
Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. 4. If the
engine does not start, repeat steps 7.1-7.4.
11. Run the engine and check for fuel system leaks. 12. Install the fuel injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair
Fuel Filler Hose: Service and Repair
Filler Tube Replacement
Removal Procedure
Important: Replacement fuel filler tube hoses do not come equipped with hose clamps. Obtain
replacement hose clamps prior to beginning this service procedure.
Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or
EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the
negative battery cable, except for those tests where battery voltage is required.
1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at
least this level. Refer to Fuel Tank Draining. 2. Remove the fuel filler cap. 3. Raise and support the
vehicle. Refer to Vehicle Lifting. 4. Remove the right rear wheel and tire. 5. Remove the right rear
wheelhouse inner liner.
6. Loosen the fuel filler tube hose clamp. 7. Disconnect the fuel filler tube, the fuel filler vent tube,
and the fresh air hose from the fuel tank.
8. Remove the fuel filler tube bracket bolts (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 7804
9. Remove the fuel filler tube (1) from the vehicle.
10. Remove the closeout grommet.
11. Separate the fresh air hose from the fuel filler tube.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 7805
1. Attach the fresh air hose to the fuel filler tube.
2. Install the closeout grommet.
3. Position the fuel filler tube (1) to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 7806
4. Position the fuel filler tube to the closeout grommet (1).
Notice: Refer to Fastener Notice.
5. Install the fuel filler tube bracket bolts (2).
Tighten the bolt to 12 N.m (106 lb in).
Important: Ensure that the fuel filler tube connecting hose is installed until it touches the fuel tank
body. The hose clamp should be located within 13 mm (1/2 in) of the end of the connecting hose.
6. Position the filler tube-to-fuel tank connecting hose and hose clamp.
Tighten the clamp to 5 N.m (44 lb in).
7. Connect the fuel filler vent tube and fresh air hose. 8. Install the inner wheelhouse liner. 9. Install
the wheel and tire.
10. Lower the vehicle from the hoist. 11. Install the fuel filler cap. 12. Perform the Service Bay
Diagnostic Test for the EVAP emission system using the scan tool. This test will verify the integrity
of the vapor handling
areas of the fuel system. See: Computers and Control Systems/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes/Service Bay Test
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 09-06-04-001 > Jan > 09 >
Fuel System - MIL ON/DTC's P0455/P0442
Fuel Filler Neck: Customer Interest Fuel System - MIL ON/DTC's P0455/P0442
TECHNICAL
Bulletin No.: 09-06-04-001
Date: January 08, 2009
Subject: Malfunction Indicator Lamp (MIL) Check Engine Light On, DTC P0442 or P0455 Set
(Perform Outlined Repair)
Models: 2005-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Condition
Some customers may comment on a check engine light on.
Upon further investigation, the technician may find DTC P0442 (EVAP small leak) or P0455 (EVAP
large leak) set as current or in history.
Cause
This condition may be caused by the rubber grommet at the fuel tank filler neck not being properly
seated. In some situations, the inner lip of the grommet may ride over the top of the filler neck,
preventing the fuel cap from tightening properly, resulting in poor sealing. This can set the small or
large leak diagnostic codes.
Correction
DO NOT replace the fuel cap for this condition. Follow the instructions listed below.
1. Inspect the rubber grommet for damage. Replace if necessary.
2. Ensure that the grommet is correctly seated to the fuel filler neck pocket.
3. If the grommet is not correctly seated, use a non-metallic tool to push down on the inner lip of
the grommet, folding it inward on the fill pipe. This will prevent the possibility of the inner lip
interfering with the fuel cap.
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 09-06-04-001 > Jan > 09 >
Fuel System - MIL ON/DTC's P0455/P0442 > Page 7815
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 09-06-04-001
> Jan > 09 > Fuel System - MIL ON/DTC's P0455/P0442
Fuel Filler Neck: All Technical Service Bulletins Fuel System - MIL ON/DTC's P0455/P0442
TECHNICAL
Bulletin No.: 09-06-04-001
Date: January 08, 2009
Subject: Malfunction Indicator Lamp (MIL) Check Engine Light On, DTC P0442 or P0455 Set
(Perform Outlined Repair)
Models: 2005-2008 Chevrolet Equinox 2006-2008 Pontiac Torrent
Condition
Some customers may comment on a check engine light on.
Upon further investigation, the technician may find DTC P0442 (EVAP small leak) or P0455 (EVAP
large leak) set as current or in history.
Cause
This condition may be caused by the rubber grommet at the fuel tank filler neck not being properly
seated. In some situations, the inner lip of the grommet may ride over the top of the filler neck,
preventing the fuel cap from tightening properly, resulting in poor sealing. This can set the small or
large leak diagnostic codes.
Correction
DO NOT replace the fuel cap for this condition. Follow the instructions listed below.
1. Inspect the rubber grommet for damage. Replace if necessary.
2. Ensure that the grommet is correctly seated to the fuel filler neck pocket.
3. If the grommet is not correctly seated, use a non-metallic tool to push down on the inner lip of
the grommet, folding it inward on the fill pipe. This will prevent the possibility of the inner lip
interfering with the fuel cap.
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 09-06-04-001
> Jan > 09 > Fuel System - MIL ON/DTC's P0455/P0442 > Page 7821
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7830
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7831
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7832
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7833
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7834
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 7835
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7841
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7842
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7843
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7844
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7845
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 7846
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge
Sender > Component Information > Technical Service Bulletins > Page 7847
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Fuel Tank Unit: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement
Fuel Tank Unit: Service and Repair Primary Fuel Tank Module Replacement
Primary Fuel Tank Module Replacement
Tools Required
J 45722 Fuel Sender Lock Ring Wrench
Removal Procedure
Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting
and have an approved container available to collect any fuel.
Notice: Clean all fuel pipe and hose connections and surrounding areas before disassembling to
avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang
with penetrating oil prior to attempting removal.
Important: NEW fuel tank module seals are necessary each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and secondary modules prior to beginning this service
procedure.
Important: The primary and secondary fuel tank modules are connected inside the fuel tank by a
formed pipe and electrical connector, the secondary fuel tank module must be removed prior to
removing the primary fuel tank module.
1. Remove the secondary fuel pump module. 2. Disconnect the electrical connectors from the
primary fuel pump module and fuel tank pressure sensor. 3. Cut the plastic strap around the fuel
tank, if necessary.
Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage
generated by handling the fuel pipes could damage the joints.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement > Page 7853
Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The
use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel
tank rotation.
4. Disconnect the fuel feed and vent lines from the fuel tank. 5. Use the J 45722 and a long
breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a
counterclockwise direction.
Notice: To prevent bending of the sending unit float arm during removal, lift the pump module up
slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.
6. Remove the primary fuel pump module assembly.
Important: Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module
is removed.
7. Discard the fuel pump module-to-tank seal. 8. If the fuel level sending unit is being replaced,
remove the fuel level sender.
Important: *
Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may
be reused if they are not damaged or warped.
* Inspect the lock ring for damage due to improper removal or installation procedures. If damage is
found, install a NEW lock ring.
* Check the lock ring for flatness.
Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat
surface using a feeler gage at 7 points.
9. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
10. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
Installation Procedure
1. If the fuel level sending unit is being replaced, install the fuel level sending unit onto the new fuel
pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement > Page 7854
2. Insert the new primary fuel pump module assembly with the level sender and the new fuel
pump-to-tank seal. Ensure the orientation tabs are
aligned.
Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace
the lock ring if necessary. Do not apply any type of lubrication in the seal groove.
Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring
will only turn in a clockwise direction.
3. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a
clockwise direction. 4. Connect the wiring harness to the primary fuel pump module and fuel tank
pressure sensor. 5. Install the secondary fuel pump module. 6. Install the fuel tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement > Page 7855
Fuel Tank Unit: Service and Repair Secondary Fuel Tank Module Replacement
Secondary Fuel Tank Module Replacement
Tools Required
J39765-A Fuel Sender Lock Ring Tool
Removal Procedure
Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting
and have an approved container available to collect any fuel.
Notice: Clean all fuel pipe and hose connections and surrounding areas before disassembling to
avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang
with penetrating oil prior to attempting removal.
Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced.
Obtain a NEW seal prior to beginning this service procedure.
1. Remove the fuel tank. 2. Disconect the EVAP vent line quick connect.
Notice: To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter
ratchet/breaker bar.
3. Use the J39765-A and remove the fuel pump module retaining ring. 4. Carefully raise the fuel
pump module until the electrical connector and suction port tube can be disconnected.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement > Page 7856
5. Disconnect the secondary level sensor electrical connector. 6. Disconnect the suction port
attaching tube by pressing down on the tab (1).
Notice: To prevent bending of the sending unit float arm during removal, lift the pump module up
slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.
7. Remove the secondary fuel pump module.
Important: Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module
is removed.
8. Discard the fuel pump module-to-tank seal. 9. If the fuel level sending unit is being replaced as
well, remove the fuel level sender.
Installation Procedure
1. If the fuel level sending unit is being replaced, install the fuel level sending unit into the new fuel
pump.
2. Connect the suction port (1). 3. Connect the secondary level sensor electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Service and Repair > Primary Fuel Tank Module Replacement > Page 7857
4. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank
seal. Ensure the orientation tabs are aligned. 5. Use the J39765-A to install the fuel pump lock ring.
6. Connect the EVAP line quick connect. 7. Install the fuel tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service Precautions
Idle Speed/Throttle Actuator - Electronic: Service Precautions
Handling Idle Air Control Valve Notice
Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The
force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak
the IAC valve in any liquid cleaner or solvent, as damage may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
Fuel Pump Relay: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7870
Fuel Pump Relay: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7871
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7872
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7873
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7874
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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> Page 7914
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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> Page 7918
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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> Page 7919
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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> Page 7920
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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> Page 7921
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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> Page 7922
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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> Page 7925
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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> Page 7926
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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> Page 7928
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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> Page 7929
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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> Page 7930
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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> Page 7931
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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> Page 7932
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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> Page 7934
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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> Page 7935
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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> Page 7937
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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> Page 7939
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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> Page 7941
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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> Page 7944
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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> Page 7945
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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> Page 7946
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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> Page 7948
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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> Page 7953
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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> Page 7954
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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> Page 7956
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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> Page 7957
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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> Page 7958
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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> Page 7959
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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> Page 7960
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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> Page 7961
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7962
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7963
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7964
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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> Page 7965
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7966
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions
> Page 7967
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
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Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7975
Accelerator Pedal Position Sensor: Diagrams
Component Connector End Views
Accelerator Pedal Position (APP) Sensor
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Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7976
Accelerator Pedal Position Sensor: Service and Repair
Accelerator Pedal Position Sensor Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel.
2. Remove the connector position assurance (CPA) from the accelerator pedal position (APP)
sensor connector. 3. Disconnect the APP sensor harness connector.
Important: Due to clearance issues, the upper attachment bolt cannot be removed from the
accelerator pedal assembly. Loose the bolt completely and leave the bolt in the component until
the assembly is removed from the vehicle.
4. Remove the APP assembly attachment bolts.
5. Remove the APP assembly from the vehicle.
Installation Procedure
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1. Install the upper attachment bolt into the APP assembly. 2. Install the APP assembly into the
vehicle.
Notice: Refer to Fastener Notice.
3. Install the remaining attachment bolts into the APP assembly.
Tighten the bolts to 25 N.m (18 lb ft).
4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt,
then pull back to confirm engagement. 5. Install the CPA to the APP sensor harness connector. 6.
Install the instrument panel left lower closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Powertrain Component Views
Top Engine Components 1 of 2 (LNJ)
1 - Throttle Actuator Control (TAC) Module 2 - Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor 3 - Air Cleaner Box
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Air Flow Meter/Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7983
Air Flow Meter/Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7984
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7985
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7986
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7987
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7988
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7989
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 7990
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8066
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8067
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8068
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8069
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8070
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8071
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8072
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8073
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8074
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8075
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8076
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8077
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 8079
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8080
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Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8081
Air Flow Meter/Sensor: Connector Views
Component Connector End Views - Continued
Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LNJ)
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Air Flow Meter/Sensor: Service and Repair
Mass Airflow Sensor Replacement
Removal Procedure
1. Remove the air cleaner intake duct. 2. Disconnect the mass air flow (MAF) sensor electrical
connector.
3. Remove the screws that retain the MAF to the air cleaner assembly. 4. Remove the MAF from
the air cleaner assembly. 5. Remove the MAF to air cleaner assembly seal.
Installation Procedure
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1. Install the seal to the MAF. 2. Install the MAF to the air cleaner assembly.
Notice: Refer to Fastener Notice.
3. Install the screws that retain the MAF to the air cleaner assembly.
Tighten the screws to 4 N.m (35 lb in).
4. Install the air cleaner intake duct
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Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Instructions > Page 8089
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Instructions > Page 8090
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Instructions > Page 8092
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Instructions > Page 8151
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Instructions > Page 8163
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8174
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8175
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8176
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8177
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8178
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8179
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8180
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8181
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8182
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8183
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8184
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 8185
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Procedures
Throttle Body: Procedures
Throttle Learn
Throttle Learn
Description
The engine control module (ECM) learns the airflow through the throttle body to ensure the correct
idle. The learned airflow values are stored within the ECM. These values are learned to adjust for
production variation and will continuously learn during the life of the vehicle to compensate for
reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to
cleaning or replacing, the values must be relearned.
A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take
several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability
to reset all learned values back to zero. A new ECM will also have values set to zero.
The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.
Conditions for Running the Throttle Learn Procedure
With Scan Tool - Reset Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 is not set.
* Ignition ON, engine OFF.
* The vehicle speed sensor (VSS) is 0 km/h (0 mph).
Without Scan Tool - Learn Procedure
* DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120,
P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205,
P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606,
P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128,
P2135, P2138, or P2176 is not set.
* The engine speed is between 450-4,000 RPM.
* The manifold absolute pressure (MAP) is greater than 5 kPa.
* The mass air flow (MAF) is greater than 2 g/s.
* The ignition 1 voltage is greater than 10 volts.
Throttle Learn
With Scan Tool - Reset Procedure
1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2.
Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow
Compensation value should equal 0 percent and the
engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.
Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code
(DTC) List - Vehicle. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
Without Scan Tool - Learn Procedure
1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual
RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3
minute run time the engine should be idling normal.
Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle
speed codes are set, clear codes so the ECM can continue to learn.
^ If the engine idle speed has not been learned the vehicle will need to be driven at speeds above
70 km/h (44 mph) with several decelerations and extended idles.
7. After the drive cycle, the engine should be idling normally.
^ If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat
step 6.
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Information > Service and Repair > Procedures > Page 8190
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that
referred you here.
Throttle Body Cleaning
Throttle Body Cleaning
Important: Over extended time and mileage, deposits may accumulate on the back of the throttle
valve plate. The source of the deposit is exhaust gas recirculation (EGR) gas. Typically these
deposits pose no problem. Occasionally the deposit may accumulate to a point where perceived
pedal effort or throttle valve movement is effected. This procedure should not be performed on
vehicles with mileage under 80 450 km (50,000 mi).
1. Remove the air intake duct.
Caution: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement
of the throttle blade could cause personal injury.
Notice: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle
valve plate.
2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the
throttle valve in order to inspect all surfaces.
Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage
fuel system components.
3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top
engine cleaner, GM P/N 1052626 (Canadian P/N
993026) or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
4. Install the air intake duct.
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Throttle Body: Removal and Replacement
Throttle Body Assembly Replacement
Removal Procedure
Important: The throttle actuator control (TAC) module is not replaceable separate of the throttle
body assembly. If the TAC module requires replacement the entire throttle body assembly must be
replaced.
1. Remove the air cleaner intake duct. 2. Remove the heater outlet pipe. 3. Cover the throttle body
opening with a shop towel and use the shop air to remove any dirt at the base of the throttle body.
4. Disconnect the TAC module electrical connector (1) by pulling up on the connector lock (2) to
release the connector from the TAC module (3).
5. Remove the throttle body bolts (2). 6. Remove the throttle body (1) from the intake manifold. 7.
Block the intake manifold opening with a clean shop towel to prevent dirt from entering. 8. Remove
the throttle body studs ONLY If replacement of stud is necessary.
Installation Procedure
Notice: Refer to Fastener Notice.
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1. Install the throttle body studs if previously removed.
Tighten the throttle body stud to 6 N.m (53 lb in).
2. Install the throttle body (1) to the intake manifold. 3. Install the throttle body bolts.
Tighten the throttle body-to-intake manifold bolts to 10 N.m (89 lb in).
4. Connect the TAC module electrical connector (1) to the TAC module (3) then press down the
connector lock (2) in order to secure the TAC
module electrical connector.
5. Install the heater outlet pipe. 6. Install the air cleaner intake duct.
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Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Throttle Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
..................................................................1-2-3-4-5-6
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
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Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
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Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Information > Diagrams > Diagram Information and Instructions > Page 8326
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8357
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8358
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8359
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8360
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8361
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8362
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8363
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8364
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8365
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8366
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8367
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8368
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8369
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8370
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8371
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8372
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8373
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8374
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8375
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8376
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8377
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8378
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8379
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8380
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8381
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8382
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8383
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8384
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8386
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Information > Diagrams > Diagram Information and Instructions > Page 8388
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8389
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8390
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information > Diagrams > Diagram Information and Instructions > Page 8391
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 8392
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8393
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 8394
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8395
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information > Diagrams > Diagram Information and Instructions > Page 8396
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8397
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8398
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8399
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information > Diagrams > Diagram Information and Instructions > Page 8400
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Information > Diagrams > Diagram Information and Instructions > Page 8401
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8402
Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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Information > Diagrams > Diagram Information and Instructions > Page 8449
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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Information > Diagrams > Diagram Information and Instructions > Page 8451
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Information > Diagrams > Diagram Information and Instructions > Page 8454
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Information > Diagrams > Diagram Information and Instructions > Page 8459
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Information > Diagrams > Diagram Information and Instructions > Page 8462
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Information > Diagrams > Diagram Information and Instructions > Page 8463
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Information > Diagrams > Diagram Information and Instructions > Page 8474
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 8479
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 8481
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 8483
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8484
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Information > Diagrams > Diagram Information and Instructions > Page 8485
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8486
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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Information > Diagrams > Diagram Information and Instructions > Page 8487
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Information > Diagrams > Diagram Information and Instructions > Page 8488
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 8489
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 8490
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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Information > Diagrams > Diagram Information and Instructions > Page 8492
The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Information > Diagrams > Diagram Information and Instructions > Page 8494
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information > Diagrams > Diagram Information and Instructions > Page 8495
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8496
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information > Diagrams > Diagram Information and Instructions > Page 8497
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8498
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 8499
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8500
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8501
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8502
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8503
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8504
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8505
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8506
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8507
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 8508
Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement
Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 8511
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 8512
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications
Ignition Cable: Specifications
Spark Plug Wire Resistance.................................................................................................................
........................4,018 ohm per meter(1,225 ohmper ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 8516
Ignition Cable: Testing and Inspection
Spark Plug Wire Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be
necessary to accurately identify conditions that may affect engine operation. Refer to the list below
for items to be inspected.
1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2.
Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following
conditions:
* Tearing
* Piercing
* Arcing
* Carbon tracking
* Corroded terminal
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the
wire and the component connected to the wire should be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 8517
Ignition Cable: Service and Repair
Spark Plug Wire Replacement
Removal Procedure
1. Remove the injector sight shield.
Notice: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug
boot only. Do not pull on the spark plug wire or the wire could be damaged.
2. Remove the spark plug wires (1) from the left side spark plugs. 3. Remove the spark plug wires
from the retaining clips (2).
4. Remove the spark plug wires (1) from the right side spark plugs. 5. Remove the spark plug wires
from the retaining clips (2). 6. Remove the spark plug wires from the ignition coil/control module. 7.
Remove the spark plug wires from the engine. 8. If you are replacing the spark plug wires, transfer
any of the following components:
* Boot heat shields
* Spark plug wire conduit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 8518
* Spark plug wire retaining clips
Installation Procedure
1. Install the spark plug wires (1) to the ignition coil/control module. 2. Install the spark plug wires
(1) to the right side spark plugs. 3. Install the spark plug wires to the retaining clips (2).
4. Install the spark plug wires (1) to the left side spark plugs. 5. Install the spark plug wires to the
retaining clips (2). 6. Install the injector sight shield.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Service and Repair
Ignition Coil: Service and Repair
Ignition Coil/Control Module Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
spark plug wires. Note the position from which the wires are removed. 4. Disconnect the ignition
coil/control module electrical connectors. 5. Remove the 4 bolts securing the ignition coil/control
module to the ignition control module bracket. 6. Remove the ignition coil/control module.
Installation Procedure
1. Install the ignition coil/control module to the ignition control module bracket.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Service and Repair > Page 8522
2. Install the 4 bolts securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
3. Connect the ignition coil/control module electrical connectors. 4. Connect the spark plug wires. 5.
Install the injector sight shield. 6. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Locations
Ignition Control Module: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 2 of 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Locations > Page 8526
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Locations > Page 8527
Ignition Control Module: Diagrams
Component Connector End Views
Ignition Control Module (ICM) (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Service and Repair > Ignition Coil/Control Module Replacement
Ignition Control Module: Service and Repair Ignition Coil/Control Module Replacement
Ignition Coil/Control Module Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
spark plug wires. Note the position from which the wires are removed. 4. Disconnect the ignition
coil/control module electrical connectors. 5. Remove the 4 bolts securing the ignition coil/control
module to the ignition control module bracket. 6. Remove the ignition coil/control module.
Installation Procedure
1. Install the ignition coil/control module to the ignition control module bracket.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Service and Repair > Ignition Coil/Control Module Replacement > Page 8530
2. Install the 4 bolts securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
3. Connect the ignition coil/control module electrical connectors. 4. Connect the spark plug wires. 5.
Install the injector sight shield. 6. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Service and Repair > Ignition Coil/Control Module Replacement > Page 8531
Ignition Control Module: Service and Repair Ignition Control Module Bracket Replacement
Ignition Control Module Bracket Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
ignition coil/control module electrical connectors. 4. Remove the spark plug wire retainer (1) from
the ignition control module bracket. 5. Remove the 4 bolts securing the ignition coil/control module
to the ignition control module bracket. 6. Position the ignition coil/control module aside out of the
way. 7. Remove the bolt (3) from the fuel injector wire harness bracket (4) and positive crankcase
ventilation (PCV) valve fresh air tube retainer. 8. Remove the engine wire harness retainers from
the ignition control module bracket studs (5).
9. Remove the nut (1) retaining the heater outlet pipe.
10. Lift pipe up slightly to gain access for the removal of the 2 ignition control module bracket bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Service and Repair > Ignition Coil/Control Module Replacement > Page 8532
11. Remove the ignition control module bracket bolts (2). 12. Remove the ignition control module
bracket nuts (6). 13. Remove the ignition control module bracket.
Installation Procedure
1. Install the ignition control module bracket.
Notice: Refer to Fastener Notice.
2. Install the ignition control module bracket nuts (6).
Tighten the nuts to 25 N.m (18 lb ft).
3. Install the ignition control module bracket bolts (2).
Tighten the bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component
Information > Service and Repair > Ignition Coil/Control Module Replacement > Page 8533
4. Install the nut (1) retaining the heater outlet pipe.
Tighten the nut to 25 N.m (18 lb ft).
5. Install the engine wire harness retainers to the ignition control module bracket studs (5). 6. Install
the bolt (3) from the fuel injector wire harness bracket (4) and PCV valve fresh air tube retainer.
Tighten the bolts to 5 N.m (44 lb in).
7. Install the ignition coil/control module to the ignition control module bracket. 8. Install the 4 bolts
securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
9. Install the spark plug wire retainer (1) to the ignition control module bracket.
10. Connect the ignition coil/control module electrical connectors. 11. Install the injector sight
shield. 12. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations
Ignition Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 8540
Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 8541
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Diagram Information and Instructions
Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagrams > Diagram Information and Instructions > Page 8546
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagrams > Diagram Information and Instructions > Page 8548
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 8585
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Diagrams > Diagram Information and Instructions > Page 8586
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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Diagrams > Diagram Information and Instructions > Page 8587
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Diagrams > Diagram Information and Instructions > Page 8588
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Diagrams > Diagram Information and Instructions > Page 8589
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Diagrams > Diagram Information and Instructions > Page 8591
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Diagrams > Diagram Information and Instructions > Page 8593
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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Diagrams > Diagram Information and Instructions > Page 8594
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Diagrams > Diagram Information and Instructions > Page 8595
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Diagrams > Diagram Information and Instructions > Page 8596
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Diagrams > Diagram Information and Instructions > Page 8597
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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Diagrams > Diagram Information and Instructions > Page 8598
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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Diagrams > Diagram Information and Instructions > Page 8599
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 8600
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Diagrams > Diagram Information and Instructions > Page 8602
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Diagrams > Diagram Information and Instructions > Page 8604
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Diagrams > Diagram Information and Instructions > Page 8607
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Diagrams > Diagram Information and Instructions > Page 8608
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Diagrams > Diagram Information and Instructions > Page 8610
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Diagrams > Diagram Information and Instructions > Page 8611
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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Diagrams > Diagram Information and Instructions > Page 8612
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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Diagrams > Diagram Information and Instructions > Page 8613
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Diagram Information and Instructions > Page 8635
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Diagrams > Diagram Information and Instructions > Page 8636
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Diagram Information and Instructions > Page 8637
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagrams > Diagram Information and Instructions > Page 8638
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 8639
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 8640
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Diagrams > Diagram Information and Instructions > Page 8641
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Diagrams > Diagram Information and Instructions > Page 8642
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
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Diagrams > Diagram Information and Instructions > Page 8643
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Page 8644
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor Replacement - Bank 1 > Page 8647
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor Replacement - Bank 1 > Page 8648
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor Replacement - Bank 1 > Page 8649
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Service and Repair > Knock Sensor Replacement - Bank 1 > Page 8650
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Top Engine Components 2 of 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Locations > Page 8655
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Locations > Page 8656
Ignition Control Module: Diagrams
Component Connector End Views
Ignition Control Module (ICM) (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control Module Replacement
Ignition Control Module: Service and Repair Ignition Coil/Control Module Replacement
Ignition Coil/Control Module Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
spark plug wires. Note the position from which the wires are removed. 4. Disconnect the ignition
coil/control module electrical connectors. 5. Remove the 4 bolts securing the ignition coil/control
module to the ignition control module bracket. 6. Remove the ignition coil/control module.
Installation Procedure
1. Install the ignition coil/control module to the ignition control module bracket.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control Module Replacement > Page
8659
2. Install the 4 bolts securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
3. Connect the ignition coil/control module electrical connectors. 4. Connect the spark plug wires. 5.
Install the injector sight shield. 6. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control Module Replacement > Page
8660
Ignition Control Module: Service and Repair Ignition Control Module Bracket Replacement
Ignition Control Module Bracket Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the injector sight shield. 3. Disconnect the
ignition coil/control module electrical connectors. 4. Remove the spark plug wire retainer (1) from
the ignition control module bracket. 5. Remove the 4 bolts securing the ignition coil/control module
to the ignition control module bracket. 6. Position the ignition coil/control module aside out of the
way. 7. Remove the bolt (3) from the fuel injector wire harness bracket (4) and positive crankcase
ventilation (PCV) valve fresh air tube retainer. 8. Remove the engine wire harness retainers from
the ignition control module bracket studs (5).
9. Remove the nut (1) retaining the heater outlet pipe.
10. Lift pipe up slightly to gain access for the removal of the 2 ignition control module bracket bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Control Module > Component Information > Service and Repair > Ignition Coil/Control Module Replacement > Page
8661
11. Remove the ignition control module bracket bolts (2). 12. Remove the ignition control module
bracket nuts (6). 13. Remove the ignition control module bracket.
Installation Procedure
1. Install the ignition control module bracket.
Notice: Refer to Fastener Notice.
2. Install the ignition control module bracket nuts (6).
Tighten the nuts to 25 N.m (18 lb ft).
3. Install the ignition control module bracket bolts (2).
Tighten the bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
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8662
4. Install the nut (1) retaining the heater outlet pipe.
Tighten the nut to 25 N.m (18 lb ft).
5. Install the engine wire harness retainers to the ignition control module bracket studs (5). 6. Install
the bolt (3) from the fuel injector wire harness bracket (4) and PCV valve fresh air tube retainer.
Tighten the bolts to 5 N.m (44 lb in).
7. Install the ignition coil/control module to the ignition control module bracket. 8. Install the 4 bolts
securing the ignition coil/control module to the ignition control module bracket.
Tighten the bolts to 4.5 N.m (40 lb in).
9. Install the spark plug wire retainer (1) to the ignition control module bracket.
10. Connect the ignition coil/control module electrical connectors. 11. Install the injector sight
shield. 12. Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System >
Ignition Relay > Component Information > Locations
Ignition Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Powertrain Component Views
Top Engine Components 2 of 2 (LNJ)
1 - Fuel Injector 5 2 - Fuel Injector 6 3 - Fuel Injector 4 4 - Fuel Injector 2 5 - Camshaft Position
Sensor (CMP) 6 - Fuel Injector 1 7 - Generator 8 - Fuel Injector 3 9 - Ignition Control Module (ICM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8672
Camshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8673
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8674
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8675
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8718
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8719
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8721
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8722
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8724
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8731
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8735
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8736
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8737
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8739
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8741
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8747
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Camshaft Position Sensor: Connector Views
Component Connector End Views
Camshaft Position (CMP) Sensor (LNJ)
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Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor Replacement
Removal Procedure
1. Remove the air cleaner inlet duct. 2. Disconnect the engine wiring harness electrical connector
from the camshaft position (CMP) sensor. 3. Remove the CMP sensor bolt (2). 4. Remove the
CMP sensor (1). 5. Inspect the CMP sensor O-rings for wear, cracks, or leakage if the sensor is
being reused. Replace the O-rings if damaged.
Installation Procedure
1. Lubricate the CMP sensor O-rings with clean engine oil.
2. Install the CMP sensor (1).
Notice: Refer to Fastener Notice.
3. Install the CMP sensor bolt (2).
Tighten the bolt to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector to the CMP sensor.
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5. Install the air cleaner inlet duct.
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Crankshaft Position Sensor: Locations
Powertrain Component Views
Rear Engine Components (LNJ)
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
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Crankshaft Position Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Crankshaft Position Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Crankshaft Position Sensor: Connector Views
Component Connector End Views
Crankshaft Position (CKP) Sensor (LNJ)
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Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the crankshaft position (CKP) sensor
electrical connector. 3. Remove the CKP sensor nut (2). 4. Remove the CKP sensor (1) from the
engine. 5. Inspect for wear, cracks, or leakage if the CKP sensor is being reused.
Installation Procedure
1. Lubricate the O-ring with clean engine oil. Replace the O-rings if damaged.
2. Install the CKP sensor (1) to the block.
Notice: Refer to Fastener Notice.
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Page 8879
3. Install the CKP sensor nut (2).
Tighten the nut to 11 N.m (97 lb in).
4. Connect the CKP sensor electrical connector. 5. Lower the vehicle.
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Page 8880
Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn
Crankshaft Position System Variation Learn
Important: The Crankshaft Position (CKP) system variation learn procedure is also required when
the following service procedures have been performed, regardless of whether DTC P0315 is set:
* An engine replacement
* A engine control module (ECM) replacement
* A crankshaft balancer replacement
* A crankshaft replacement
* A CKP sensor replacement
*
Any engine repairs which disturb the crankshaft to CKP sensor relationship.
Important: The ECM monitors certain component signals to determine if all the conditions are met
to continue with the CKP System Variation Learn Procedure. The scan tool only displays the
condition that inhibits the procedure. The scan tool displays the signals of the following
components:
* CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set.
* Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable
DTC that set.
* Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the
engine until the engine coolant temperature reaches the correct temperature.
1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except
DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle
for the applicable DTC that set. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions
3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following:
1. Block drive wheels. 2. Set parking brake. 3. DO NOT apply brake pedal. 4. Cycle ignition from
OFF to ON. 5. Apply and hold brake pedal for the duration of the procedure. 6. Start and idle
engine. 7. Turn the air conditioning (A/C) OFF. 8. The vehicle must remain in Park or Neutral.
Important: While the learn procedure is in progress, release the throttle immediately when the
engine starts to decelerate. The engine control is returned to the operator and the engine responds
to throttle position after the learn procedure is complete.
9. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC
P0315 ran and passed, the CKP variation learn
procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is
present, refer to Diagnostic Trouble Code (DTC) List - Vehicle and perform the appropriate
diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Descriptions
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order
to store the CKP system variation values in the
ECM memory.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest
for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds
Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8897
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8898
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8899
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8900
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8901
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 8902
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations > Page 8906
Front Engine Components 2 of 2 (LNJ)
1 - A/C Compressor Clutch 2 - Knock Sensor (KS) 2 3 - Starter 4 - A/C Refrigerant Pressure
Sensor
Rear Engine Components (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Locations > Page 8907
1 - Engine Coolant Temperature (ECT) Sensor 2 - Ignition Control Module (ICM) 3 - Manifold
Absolute Pressure (MAP) Sensor 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Throttle Actuator
Control (TAC) Module 6 - Generator 7 - Knock Sensor (KS) 1 8 - Engine Coolant Heater 9 Crankshaft Position (CKP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions
Knock Sensor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8910
Knock Sensor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8911
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8912
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8913
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8914
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8915
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8916
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8993
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8994
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 8995
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9006
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9007
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9008
Knock Sensor: Connector Views
Component Connector End Views - Continued
Knock Sensor (KS) 1 (LNJ)
Knock Sensor (KS) 2 (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9009
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Diagrams > Page 9010
Knock Sensor: Service Precautions
Knock Sensor Service Caution
Caution: Hot engine coolant may cause severe burns. Although the cooling system has been
drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of
the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement - Bank 1
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 1
Knock Sensor Replacement - Bank 1
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. If equipped with front wheel drive
(FWD), disconnect the engine wiring harness electrical connector (1) from the knock sensor.
3. If equipped with all wheel drive (AWD), disconnect the engine wiring harness electrical connector
(1) from the knock sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 9013
4. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 9014
2. If equipped with AWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor.
3. If equipped with FWD, Connect the engine wiring harness electrical connector (1) to the knock
sensor. 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 9015
Knock Sensor: Service and Repair Knock Sensor Replacement - Bank 2
Knock Sensor Replacement - Bank 2
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the engine wiring harness
electrical connector (2) from the knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.
Installation Procedure
Important: DO NOT apply threadlocker to the sensor threads. The sensor threads are coated at the
factory and applying additional threadlocker affects the sensor's ability to detect detonation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Knock Sensor > Component Information > Service and Repair > Knock Sensor Replacement - Bank 1 > Page 9016
Notice: Refer to Fastener Notice.
1. Position the knock sensor to the engine and tighten the bolt.
Tighten the bolt to 25 N.m (18 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the knock sensor. 3. Lower the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire Warranty
Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire Warranty
Extension > Page 9025
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire Warranty
Extension > Page 9026
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Recalls for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug Wire Warranty
Extension > Page 9027
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug
Wire Warranty Extension
Technical Service Bulletin # 10250 Date: 110131
Campaign - Spark Plug Wire Warranty Extension
SPECIAL COVERAGE
Bulletin No.: 10250
Date: January 31, 2011
Subject: 10250 - Special Coverage Adjustment - Spark Plug Wire Warranty Extension
Models:
2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped with a 3.4L Engine (LNJ) 2008
Chevrolet Express, Silverado 2008 GMC Savana, Sierra Equipped with 4.3L Engine (LU3)
Condition
Some customers of 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles
equipped with a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra
vehicles equipped with a 4.3L engine (LU3) may comment about rough engine operation and the
illumination of the Check Engine Light. This may be caused by spark plug wire boots that do not
provide a sufficiently robust dielectric seal to withstand the high voltage required to fire the spark
plugs.
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000
miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. Dealers are to replace all spark plug wires and, if necessary, the
spark plug. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle
Service Contracts, all eligible claims with repair orders on or after January 5, 2011, are covered by
this special coverage and must be submitted using the labor operation codes provided with this
bulletin. Claims with repair orders prior to January 5, 2011, must be submitted to the Service
Contract provider.
Vehicles Involved
Involved are 2007-2009 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with
a 3.4L engine (LNJ), and 2008 Chevrolet Express, Silverado; GMC Savana, Sierra vehicles
equipped with a 4.3L engine (LU3).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate
Vehicle History (GMVIS2) Application in the Applicable Warranties section. Dealership technicians
should always check this site to confirm vehicle involvement prior to beginning any required
inspections and/or repairs.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Customer
Care and Aftersales (GMCC&A;).
* Not eligible for RIM initially for US and Canada, until sufficient inventory levels are reached.
Service Procedure
1. Connect a scan tool and start the engine. 2. Determine if any cylinders have a misfire condition.
- If a misfire condition is present or diagnostic trouble codes (DTCs) PO300-PO306 are current or
set in history, remove all of the spark plug wires and replace them with new spark plug wire set.
Refer to Spark Plug Wire Replacement in SI. Proceed to Step 3.
- If a misfire condition is NOT present in any cylinder, do NOT replace the spark plug wires. Refer
to the appropriate diagnostic information in
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug
Wire Warranty Extension > Page 9033
SI to determine the cause of the problem. Repairs that are not related to this Special Coverage
must be billed as warranty, customer pay, or goodwill.
3. Remove the spark plug from the misfiring cylinder. The spark plug should have evidence of
carbon tracking (1). Replace the spark plug that shows
evidence of carbon tracking. Refer to Spark Plug Replacement in SI.
4. Clear DTCs using a scan tool.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will
be handled by the Customer Assistance Center, not by dealers.
A General Motors Customer Reimbursement Procedure and Claim Form is included with the
customer letter.
Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific
procedures regarding customer reimbursement and the form.
Customer Reimbursement - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the condition described
in this bulletin are to be submitted to the dealer prior to or by January 31, 2012. Repairs must have
occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000
kilometers, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service
Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
dealership.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Warranty Transaction Information
Submit a transaction using the table below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug
Wire Warranty Extension > Page 9034
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the
customer.
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Disclaimer
Owner Letter
Owner Letter
January 2011
Dear General Motors Customer:
As the owner of a 2007-2009 model year Chevrolet Equinox or Pontiac Torrent vehicle, or a 2008
Chevrolet Express, Silverado; GMC Savana or Sierra vehicle, your satisfaction with our product is
very important to us.
This letter is intended to make you aware that some 2007-2009 model year Chevrolet Equinox and
Pontiac Torrent vehicles, and some 2008 Chevrolet Express, Silverado; GMC Savana, and Sierra
vehicles may exhibit rough engine operation and the illumination of the Check Engine Light. This
may be caused by spark plug wire boots that do not provide a sufficiently robust dielectric seal to
withstand the high voltage required to fire the spark plugs.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the spark
plug wires. If this condition occurs on your 2007-2009 model year Chevrolet Equinox or Pontiac
Torrent vehicle, or 2008 Chevrolet Express, Silverado; GMC Savana or Sierra vehicle within 10
years of the date your vehicle was originally placed in service or 120,000 miles (193.000 km),
whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for
conditions other than the condition described above is not covered under this special coverage
program.
What You Should Do: If you believe that your vehicle has the condition described above, repairs
and adjustments qualifying under this special coverage must be performed by a General Motors
dealer. You may want to contact your GM dealer to find out how long they will need to have your
vehicle so that you may schedule the appointment at a time that is convenient for you. This will also
allow your dealer to order parts if they are not already in stock. Keep this letter with your other
important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to request
reimbursement if you have paid for repairs for the special coverage condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must be
received by GM by January 31, 2012. If you have any questions or need any assistance to better
understand related repairs, please contact your dealer.
If you have questions related to a potential reimbursement, please contact the appropriate
Customer Assistance Center at the number listed below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 10250 > Jan > 11 > Campaign - Spark Plug
Wire Warranty Extension > Page 9035
We are sorry for any inconvenience you may experience; however we have taken this action in the
interest of your continued satisfaction with our products.
Jim Moloney
General Director,
Customer and Relationship Services
Enclosure
10250
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 9036
Spark Plug: Specifications
Spark Plug Gap....................................................................................................................................
.........................................................1.52 mm (0.60 in)
Spark Plug Torque
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
Spark Plug Type
............................................................................................................................................
Information not supplied by the manufacturer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 9037
Spark Plug: Testing and Inspection
Spark Plug Inspection
Spark Plug Usage
* Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
* Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling-Colder plug
- Pre-ignition causing spark plug and/or engine damage-Hotter plug
Spark Plug Inspection
* Inspect the terminal post (1) for damage.
- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should
NOT move.
* Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the
following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
* Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack
instead of the electrodes (3, 4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 9038
* Inspect for evidence of improper arcing.
- Measure the gap between the center electrode (4) and the side electrode (3) terminals. An
excessively wide electrode gap can prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
* A rattling sound indicates internal damage.
* A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
* Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during installation.
Spark Plug Visual Inspection
* Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal
combustion by-products from fuels with additives.
* Carbon fouled-Dry, fluffy, black carbon or soot caused by the following conditions:
- Rich fuel mixtures
* Leaking fuel injectors
* Excessive fuel pressure
* Restricted air filter element
* Incorrect combustion
- Reduced ignition system voltage output
* Weak coils
* Worn ignition wires
* Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that
normal combustion deposits may not burn off.
* Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless
they form into a glazing over the electrode.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 9039
Spark Plug: Service and Repair
Spark Plug Replacement
Removal Procedure
Notice: Observe the following service precautions:
* Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from
a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads.
* Clean the spark plug recess area before removing the spark plug. Failure to do so can result in
engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the
cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.
* Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either
hotter or colder than those specified for the vehicle. Installing spark plugs of another type can
severely damage the engine.
1. Remove the spark plug wires from the spark plugs.
2. Remove the spark plugs (1) from the cylinder head.
Installation Procedure
Notice: It is important to check the gap of all new and reconditioned spark plugs before installation.
Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an
accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor
engine performance and may even damage the engine.
1. Gap the spark plugs to the specifications. Refer to Ignition System Specifications.
Notice: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if
necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can
cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque
specifications carefully. Over or under-tightening can also cause severe damage to engine or spark
plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Technical Service Bulletins > Page 9040
Notice: Refer to Component Fastener Tightening Notice.
Important: ONLY when the cylinder head is replaced with a NEW cylinder head, the FIRST time the
spark plugs are installed, tighten the spark plugs to 20 N.m (15 lb ft). All subsequent tightening of
the spark plugs, tighten to 15 N.m (11 lb ft).
2. Install the spark plugs to the cylinder head.
Tighten the spark plugs to 15 N.m (11 lb ft).
3. Install the spark plug wires to the spark plugs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
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Information > Locations > Page 9047
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
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Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Shift Lever Components
Below The Shifter
1 - Instrument Panel Trim 2 - Console Arm Rest 3 - Cigar Lighter 4 - Shift Lock Control Solenoid
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Locations > Page 9051
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid
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Specifications > AF33-5 - Automatic Transaxle
Shift Solenoid: Specifications AF33-5 - Automatic Transaxle
Shift Solenoid Valve State and Gear Ratio
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Specifications > AF33-5 - Automatic Transaxle > Page 9056
Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission
Shift Solenoid Valve State and Gear Ratio
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AF33-5 - Automatic Transaxle
Shift Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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AF33-5 - Automatic Transaxle > Page 9059
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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AF33-5 - Automatic Transaxle > Page 9060
Shift Solenoid: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
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AF33-5 - Automatic Transaxle > Page 9061
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
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Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Diagram Information and Instructions > Page 9064
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagram Information and Instructions > Page 9065
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Diagram Information and Instructions > Page 9066
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Diagram Information and Instructions > Page 9067
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagram Information and Instructions > Page 9068
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Diagram Information and Instructions > Page 9069
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Diagram Information and Instructions > Page 9070
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Diagram Information and Instructions > Page 9071
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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Diagram Information and Instructions > Page 9072
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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Diagram Information and Instructions > Page 9073
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Diagram Information and Instructions > Page 9149
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Diagram Information and Instructions > Page 9150
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Diagram Information and Instructions > Page 9151
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Diagram Information and Instructions > Page 9152
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 9153
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 9154
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Diagram Information and Instructions > Page 9155
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Diagram Information and Instructions > Page 9156
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagram Information and Instructions > Page 9157
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagram Information and Instructions > Page 9158
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagram Information and Instructions > Page 9159
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 9160
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Diagram Information and Instructions > Page 9161
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Diagram Information and Instructions > Page 9162
Shift Solenoid: Connector Views
Component Connector End Views - Continued
Shift Solenoid 1 (AF33-5)
Shift Solenoid 2 (AF33-5)
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Diagram Information and Instructions > Page 9163
Shift Solenoid 3 (AF33-5)
Shift Solenoid 4 (AF33-5)
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Diagram Information and Instructions > Page 9164
Shift Solenoid 5 (AF33-5)
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Diagram Information and Instructions > Page 9166
Shift Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
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Page 9167
Shift Solenoid: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly. 7.
Remove the 2 control valve body bolts (4) M6 x 65.
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Page 9168
8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6
x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
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Page 9169
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
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Information > Locations > AF33-5 - Automatic Transaxle
Torque Converter Clutch Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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Information > Locations > AF33-5 - Automatic Transaxle > Page 9175
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Torque Converter Clutch Solenoid: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
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Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
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Information > Locations > AF33-5 - Automatic Transaxle > Page 9178
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
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Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information > Diagrams > Diagram Information and Instructions > Page 9267
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information > Diagrams > Diagram Information and Instructions > Page 9270
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information > Diagrams > Diagram Information and Instructions > Page 9271
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 9276
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 9277
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 9278
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 9279
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Lock Up Pressure Control Solenoid (SLU) (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 9280
Torque Converter Clutch Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 9286
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 9287
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 9288
Transmission Control Module (TCM) X3 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 9289
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9292
7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9293
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9294
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Transmission and
Drivetrain/Automatic
Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic
Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9295
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Sensors and Switches Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Position
Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9296
1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
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Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9297
5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Sensors and Switches
Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Position
Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission > Page 9298
Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with the correct software and calibrations, DTC P0602 will be
erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Transmission
and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and
General Diagnostics/AF33-5 - Automatic Transaxle/Transmission Adaptive Learn and
Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Differential > Control Unit, Differential Lock > Component Information >
Service and Repair > Rear Differential Clutch Control Module Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Differential > Control Unit, Differential Lock > Component Information >
Service and Repair > Rear Differential Clutch Control Module Replacement > Page 9304
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Diagrams > Page 9310
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information >
Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information >
Locations > Page 9314
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views > Page 9322
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views > Page 9323
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views > Page 9324
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9327
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
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Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9328
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9333
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9334
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9335
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9336
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9337
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 9338
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 9339
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 9340
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 9341
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9344
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9345
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9346
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9347
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9348
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 9354
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 9355
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 9356
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > Page 9357
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-01-38-003 > Jun > 08 > Engine Controls - A/C Not Cold
Enough/Int. Operation
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - A/C Not Cold
Enough/Int. Operation
TECHNICAL
Bulletin No.: 08-01-38-003
Date: June 23, 2008
Subject: Air Conditioning Not Cold Enough, Intermittent A/C Operation Or Occasional Warm Air
From Instrument Panel Air Outlets (Reprogram ECM)
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
with 3.4L Engine (VIN F - RPO LNJ)
Built Prior to VIN Breakpoint 86075512
Condition
Some customers may comment that the air conditioning (A/C) is not cold enough. Others may
comment on intermittent A/C operation or occasional warm air from the instrument panel air outlets.
Cause
This condition may be caused by a software anomaly that causes the compressor to stay off for too
long.
Correction
A revised calibration has been developed to address this condition. Technicians are to reprogram
the Engine Control Module (ECM) using SPS with the latest software available on TIS2WEB. Refer
to the Engine Control Module Programming and Setup (LNJ) procedure in SI for more information.
As always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-04-026C > Aug > 10 >
Engine/Transmission - Aftermarket Calibrations
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations
INFORMATION
Bulletin No.: 09-06-04-026C
Date: August 13, 2010
Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas
Engines Using Tech 2(R) or Global Diagnostic System (GDS)
Models:
2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009
HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only
Attention:
This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines,
refer to the latest version of Corporate Bulletin Number 08-06-04-006G.
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System).
General Motors is identifying an increasing number of engine, transmission and catalytic converter
part failures that are the result of non-GM (aftermarket) engine and transmission control
calibrations being used.
When alteration to the GM-released engine or transmission control calibrations occurs, it subjects
powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear
axle) to stresses that were not tested by General Motors. It is because of these unknown stresses,
and the potential to alter reliability, durability and emissions performance, that GM has adopted a
policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining
warranty coverage, to the powertrain and driveline components whenever the presence of a
non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is
subsequently removed.
Warranty coverage is based on the equipment and calibrations that were released on the vehicle at
time of sale, or subsequently updated by GM. That's because GM testing and validation matches
the calibration to a host of criteria that is essential to assure reliability, durability and emissions
performance over the life of the warranty coverage and beyond. Stresses resulting from
calibrations different from those tested and released by GM can damage or weaken components,
leading to poor performance and or shortened life.
Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same
emissions performance standards as GM issued calibrations. Depending on state statutes,
individuals who install engine control module calibrations that put the vehicle outside the
parameters of emissions certification standards may be subject to fines and/or penalties.
This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM
recommends performing this check whenever a hard part failure is seen on internal engine or
transmission components, or before an engine assembly or transmission assembly is being
replaced under warranty. It is also recommended that the engine calibration verification procedure
be performed whenever diagnostics indicate that catalytic converter replacement is indicated.
The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a
picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing
any V8 gas powered engine replacement.
If a non-GM calibration is found and verification has taken place through GM, the remaining
powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be
notified. This block prevents any UNAUTHORIZED warranty claim submission.
1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select:
Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID
Information or I/M Information System if the Module ID Information selection is not available. 7. *If
"I/M information System" was selected, it may be necessary to select "Vehicle Information" in order
to display the calibration information.
‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain
the CVN information.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-04-026C > Aug > 10 >
Engine/Transmission - Aftermarket Calibrations > Page 9371
8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine
Calibration IDs and Verification Numbers as
shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair
order.
Note All pictures must be sent as a.jpg file.
9. E-mail a copy of the picture to
[email protected]. In the subject line of the e-mail include the
phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
10. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
11. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification
Number Screen
If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then
perform the following steps:
1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90
seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle.
Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation.
‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds
again. Turn ON the ignition and observe the
same screen for proper operation.
Retrieving Calibrations From a Global A Vehicle
This information applies to the 2010 Camaro and is typical of the procedure that will be used on
Global A vehicles.
1. Turn OFF the ignition.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-04-026C > Aug > 10 >
Engine/Transmission - Aftermarket Calibrations > Page 9372
2. Connect the MDI to the Data Link Connector (DLC) of the vehicle.
Note Use the USB port to make the following MDI connection:
3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from
TIS2WEB.
Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS
was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to
download.
4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID
Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect.
10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11.
Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow
the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine
OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic
Screen will appear.
Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in
Step 18.
18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID
Information. 22. The Diagnostics page will appear.
Typical View of GDS Calibration History Screen
Note GDS is capable of displaying up to 10 Calibration History events.
23. Select: Calibration History from the drop down menu in order to display the following items on
the screen:
- Calibration History Buffer
- Number of Calibration History Events Stored
- Calibration Part Number History
- Calibration Verification Number History
24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and
retain a copy of the screenshot with the repair order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-04-026C > Aug > 10 >
Engine/Transmission - Aftermarket Calibrations > Page 9373
Note All pictures must be sent as a.jpg file.
27. E-mail a copy of the screenshot to
[email protected]. In the subject line of the e-mail
include the phrase "V8 Cal" as well as the complete VIN
and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC.
Include a brief description of the customer concern and cause of the concern.
Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail
reply will advise the dealer if the calibrations are OEM.
28. Allow two hours for the PQC to verify the calibrations and set up the case details.
‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM
Technical Assistance to discuss warranty
concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be
directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada).
29. You may call the PQC two hours after submitting the e-mail for authorization to replace the
assembly. This will provide them time to receive,
review and set up a case on the request. Please be prepared to provide all the usual
documentation that is normally required when requesting an assembly authorization from the PQC.
Warranty Information
- The Dealership Service Management must be involved in any situation that would justify the use
of labor operation Z1111.
- Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the
situation.
- All claims will have to be routed to the FOM (WM in Canada) for approval.
- Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected
Tampering or Vehicle Modifications for important information.
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-01-38-003 > Jun > 08 > Engine Controls A/C Not Cold Enough/Int. Operation
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/C
Not Cold Enough/Int. Operation
TECHNICAL
Bulletin No.: 08-01-38-003
Date: June 23, 2008
Subject: Air Conditioning Not Cold Enough, Intermittent A/C Operation Or Occasional Warm Air
From Instrument Panel Air Outlets (Reprogram ECM)
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
with 3.4L Engine (VIN F - RPO LNJ)
Built Prior to VIN Breakpoint 86075512
Condition
Some customers may comment that the air conditioning (A/C) is not cold enough. Others may
comment on intermittent A/C operation or occasional warm air from the instrument panel air outlets.
Cause
This condition may be caused by a software anomaly that causes the compressor to stay off for too
long.
Correction
A revised calibration has been developed to address this condition. Technicians are to reprogram
the Engine Control Module (ECM) using SPS with the latest software available on TIS2WEB. Refer
to the Engine Control Module Programming and Setup (LNJ) procedure in SI for more information.
As always, make sure your Tech 2(R) is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/Start Discharged
or Low Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 9383
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 9389
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 9396
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Shift Lever Components
Below The Shifter
1 - Instrument Panel Trim 2 - Console Arm Rest 3 - Cigar Lighter 4 - Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9400
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > AF33-5 - Automatic
Transaxle
Shift Solenoid: Specifications AF33-5 - Automatic Transaxle
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > AF33-5 - Automatic
Transaxle > Page 9405
Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Shift Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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> Page 9409
Shift Solenoid: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
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> Page 9410
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
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Shift Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Instructions > Page 9511
Shift Solenoid: Connector Views
Component Connector End Views - Continued
Shift Solenoid 1 (AF33-5)
Shift Solenoid 2 (AF33-5)
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Shift Solenoid 3 (AF33-5)
Shift Solenoid 4 (AF33-5)
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Shift Solenoid 5 (AF33-5)
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Shift Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
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Shift Solenoid: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly. 7.
Remove the 2 control valve body bolts (4) M6 x 65.
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8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6
x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
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Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 9518
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Automatic Transmission/Transaxle/Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic
Transmission/Service Fast Learn Adapts) .
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Torque Converter Clutch Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Torque Converter Clutch Solenoid: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
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Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
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22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
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Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 9530
Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 9531
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Information and Instructions > Page 9532
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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Information and Instructions > Page 9560
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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Information and Instructions > Page 9561
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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Information and Instructions > Page 9562
View of the connector when released from the component.
View of another type of Micro 64 connector.
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Information and Instructions > Page 9563
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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Information and Instructions > Page 9564
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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Information and Instructions > Page 9569
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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Information and Instructions > Page 9571
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Information and Instructions > Page 9572
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Information and Instructions > Page 9574
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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Information and Instructions > Page 9576
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Information and Instructions > Page 9577
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Information and Instructions > Page 9578
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Information and Instructions > Page 9579
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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Information and Instructions > Page 9580
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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Information and Instructions > Page 9586
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Information and Instructions > Page 9590
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Information and Instructions > Page 9594
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Information and Instructions > Page 9603
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Information and Instructions > Page 9604
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Information and Instructions > Page 9605
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Information and Instructions > Page 9614
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Information and Instructions > Page 9615
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Information and Instructions > Page 9616
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Information and Instructions > Page 9617
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 9618
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 9619
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Information and Instructions > Page 9620
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information and Instructions > Page 9621
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 9622
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Information and Instructions > Page 9623
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 9624
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information and Instructions > Page 9625
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 9626
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 9627
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 9628
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Lock Up Pressure Control Solenoid (SLU) (AF33-5)
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 9629
Torque Converter Clutch Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 9635
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Shift Lever Components
Below The Shifter
1 - Instrument Panel Trim 2 - Console Arm Rest 3 - Cigar Lighter 4 - Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9639
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > AF33-5 - Automatic Transaxle
Shift Solenoid: Specifications AF33-5 - Automatic Transaxle
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > AF33-5 - Automatic Transaxle > Page
9644
Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Shift Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 9647
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 9648
Shift Solenoid: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 9649
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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9652
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
9653
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9654
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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9655
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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9656
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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9657
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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9658
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
9659
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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9660
6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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9683
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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9684
View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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9689
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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9690
7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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9691
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9698
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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9701
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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9703
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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9708
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9712
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9717
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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9728
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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9736
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Shift Solenoid: Connector Views
Component Connector End Views - Continued
Shift Solenoid 1 (AF33-5)
Shift Solenoid 2 (AF33-5)
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Shift Solenoid 3 (AF33-5)
Shift Solenoid 4 (AF33-5)
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Shift Solenoid 5 (AF33-5)
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Shift Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
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Shift Solenoid: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly. 7.
Remove the 2 control valve body bolts (4) M6 x 65.
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8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6
x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
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2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
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Torque Converter Clutch Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Torque Converter Clutch Solenoid: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
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Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
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22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Instructions > Page 9770
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Instructions > Page 9771
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9778
* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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Instructions > Page 9779
* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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Instructions > Page 9781
To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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Instructions > Page 9782
1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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Instructions > Page 9783
3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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Instructions > Page 9784
View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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Instructions > Page 9785
7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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Instructions > Page 9786
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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Instructions > Page 9787
4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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Instructions > Page 9789
4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Instructions > Page 9791
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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Instructions > Page 9792
9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9797
* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9798
* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9799
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9800
View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Instructions > Page 9801
View of the connector when released from the component.
View of another type of Micro 64 connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9802
Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
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Instructions > Page 9803
4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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Instructions > Page 9804
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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Instructions > Page 9805
The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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Instructions > Page 9806
2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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Instructions > Page 9807
7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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Instructions > Page 9808
pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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Instructions > Page 9809
After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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Instructions > Page 9810
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Instructions > Page 9811
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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Instructions > Page 9812
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Instructions > Page 9813
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Instructions > Page 9814
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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Instructions > Page 9815
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Instructions > Page 9816
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Instructions > Page 9817
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Instructions > Page 9818
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9827
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9828
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Instructions > Page 9829
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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Instructions > Page 9830
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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Instructions > Page 9831
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Instructions > Page 9832
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Instructions > Page 9833
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Instructions > Page 9834
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Instructions > Page 9836
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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Instructions > Page 9837
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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Instructions > Page 9838
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Instructions > Page 9839
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Instructions > Page 9840
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Instructions > Page 9842
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Instructions > Page 9843
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Instructions > Page 9844
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Instructions > Page 9845
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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Instructions > Page 9846
3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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Instructions > Page 9847
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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Instructions > Page 9849
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Instructions > Page 9853
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Instructions > Page 9854
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Instructions > Page 9855
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Instructions > Page 9856
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9857
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Instructions > Page 9858
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Instructions > Page 9859
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Instructions > Page 9860
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Instructions > Page 9861
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9862
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Instructions > Page 9863
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9864
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9865
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9866
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9867
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Lock Up Pressure Control Solenoid (SLU) (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and
Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 9868
Torque Converter Clutch Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent
Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid
Leaking From A/T Vent > Page 9877
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H
> Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E
> Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 9887
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H >
Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips
Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-07-30-012B > Mar > 11 > A/T No Reverse/3rd or 5th Gear/MIL ON/DTC P0776
Clutch: Customer Interest A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776
TECHNICAL
Bulletin No.: 09-07-30-012B
Date: March 08, 2011
Subject: No Reverse, 3rd or 5th, Check Engine Light Illuminated, DTC P0776 (Replace 3-5
Reverse Clutch Plate (Waved))
Models:
2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE All Equipped with 6T70/75 6-Speed Automatic
Transmission (RPOs MH2, MH4, MH6 or MY9)
Supercede: This bulletin is being revised to update the information. Please discard Corporate
Bulletin Number 09-07-30-012A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment about an SES light and/or no reverse and may also comment on a
slip / flare or harsh shifts in drive range 3rd and/or 5th gear. Upon investigation, the technician may
find DTC P0776 (Clutch Pressure Control (PC) Solenoid 2 - Stuck Off) set. Any one of the following
codes may set independent of each other as a result of this wave plate breaking: P0777, P2723,
P0717, P0716, P2715, P2714.
Cause
This condition may be caused by a broken 35R clutch wave plate allowing the apply piston to
over-stroke, causing the piston to leak and causing loss of apply. This normally will not occur
before approximately 32,000 km (20,000 mi). Debris generated by the condition can affect the
operation of the speed sensors and other clutches.
Correction
Important It is recommended that a new plate be installed any time the transmission is
disassembled for any reason.
Important The control solenoid (w/body and TCM) valve assembly should not be washed in a parts
cleaner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-07-30-012B > Mar > 11 > A/T No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9901
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-07-30-012B > Mar > 11 > A/T No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9902
Important Debris generated by the condition must be cleaned from the entire transmission and the
pump fluid filter (201) and the control solenoid filter plate (16) must be replaced. Failure to separate
the case halves, disassemble the transmission, clean the debris and replace the pump fluid filter
(201) and the control solenoid filter plate (16) could lead to repeat transmission damage and
repairs.
A new 3-5 reverse clutch plate (WAVED), P/N 24254103 (423), has been released to address this
condition. Refer to SI for the appropriate repair instructions.
A broken 35R wave plate can generate varying amounts of debris inside the transmission. In most
cases this debris has not passed through the pump fluid filter (201) so has not caused damage to
the pump, valve bodies or torque converter. This debris can be cleaned and the transmission
successfully repaired.
In summary the following steps should be taken:
1. After removing the transmission from the vehicle, remove the case cover assembly (35). Inspect
the case cover for damage. This part is serviced
and can be replaced if it is damaged.
2. Remove the 35R / 456 clutch housing assembly (422) and inspect it for a broken 35R wave plate
(423). 3. Inspect the case (21) for damage. If the case is damaged, the transmission must be
replaced as the case is not serviced. If the case is not damaged,
proceed with the tear down and inspection. Any possible damage is typically confined to the case
lugs. If the clutch plates can move freely to engage or release the clutch packs, the transmission
should not be replaced. If the snap ring grooves are not damaged and will securely retain the snap
rings, the transmission should not be replaced. Peening or wear of the edge of the case lugs that
engage the clutch plates is normal and acceptable and not cause for transmission replacement.
4. Remove the control valve body cover (1), control solenoid (w/body and TCM) valve assembly
(15) and filter plate assembly (16). 5. Inspect the filter plate assembly (16) for the presence of
metallic debris on the screens.
- If there is no debris on the screens, the pump fluid filter was effective and there is no debris in the
pump or torque converter. Therefore the pump, torque converter and valve body do not need to be
replaced. The transmission should be repaired.
- If there is debris on the screens, the pump and torque converter should be inspected further.
Refer to SI procedure Transmission Fluid Pump Cleaning and Inspection for the pump. Refer to SI
procedure Torque converter Diagnosis for the section Torque Converter Replacement Guide.
- Fine metal particles that you cannot feel (traces of metal flakes/gray color to the fluid) are not
reasons to replace the torque converter.
- Metal chips/debris that you can feel or that are found in the converter, or when flushing the cooler
and cooler lines, indicate the torque converter should be replaced.
6. The valve body must be disassembled and cleaned, refer to the latest version of Corporate
Bulletin Number 08-07-30-005 for direction. 7. The transmission case halves must be separated,
internal components removed and all parts thoroughly cleaned. Be sure to clean the speed
sensors,
both input (ISS) and output (OSS). These sensors are magnetic and will attach and hold any
ferrous material. Failure to clean these sensors may result in DTCs. A new pump fluid filter must be
installed.
Notice
The front differential carrier assembly (31) teeth are marked with notches to identify gear ratio (see
picture above). Do not confuse these marks with
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-07-30-012B > Mar > 11 > A/T No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9903
tooth damage. Do not replace the gear for this condition.
Important 2007-2008 applications - when assembling these transmissions, inspect the control valve
channel upper plate (301) to make sure that it contains the slot as indicated above. Plates installed
that do not include this slot may result in DTCs.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 09-07-30-012B > Mar > 11 > A/T No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9904
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks
Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-07-30-012B > Mar >
11 > A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776
Clutch: All Technical Service Bulletins A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776
TECHNICAL
Bulletin No.: 09-07-30-012B
Date: March 08, 2011
Subject: No Reverse, 3rd or 5th, Check Engine Light Illuminated, DTC P0776 (Replace 3-5
Reverse Clutch Plate (Waved))
Models:
2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE All Equipped with 6T70/75 6-Speed Automatic
Transmission (RPOs MH2, MH4, MH6 or MY9)
Supercede: This bulletin is being revised to update the information. Please discard Corporate
Bulletin Number 09-07-30-012A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment about an SES light and/or no reverse and may also comment on a
slip / flare or harsh shifts in drive range 3rd and/or 5th gear. Upon investigation, the technician may
find DTC P0776 (Clutch Pressure Control (PC) Solenoid 2 - Stuck Off) set. Any one of the following
codes may set independent of each other as a result of this wave plate breaking: P0777, P2723,
P0717, P0716, P2715, P2714.
Cause
This condition may be caused by a broken 35R clutch wave plate allowing the apply piston to
over-stroke, causing the piston to leak and causing loss of apply. This normally will not occur
before approximately 32,000 km (20,000 mi). Debris generated by the condition can affect the
operation of the speed sensors and other clutches.
Correction
Important It is recommended that a new plate be installed any time the transmission is
disassembled for any reason.
Important The control solenoid (w/body and TCM) valve assembly should not be washed in a parts
cleaner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-07-30-012B > Mar >
11 > A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9914
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-07-30-012B > Mar >
11 > A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9915
Important Debris generated by the condition must be cleaned from the entire transmission and the
pump fluid filter (201) and the control solenoid filter plate (16) must be replaced. Failure to separate
the case halves, disassemble the transmission, clean the debris and replace the pump fluid filter
(201) and the control solenoid filter plate (16) could lead to repeat transmission damage and
repairs.
A new 3-5 reverse clutch plate (WAVED), P/N 24254103 (423), has been released to address this
condition. Refer to SI for the appropriate repair instructions.
A broken 35R wave plate can generate varying amounts of debris inside the transmission. In most
cases this debris has not passed through the pump fluid filter (201) so has not caused damage to
the pump, valve bodies or torque converter. This debris can be cleaned and the transmission
successfully repaired.
In summary the following steps should be taken:
1. After removing the transmission from the vehicle, remove the case cover assembly (35). Inspect
the case cover for damage. This part is serviced
and can be replaced if it is damaged.
2. Remove the 35R / 456 clutch housing assembly (422) and inspect it for a broken 35R wave plate
(423). 3. Inspect the case (21) for damage. If the case is damaged, the transmission must be
replaced as the case is not serviced. If the case is not damaged,
proceed with the tear down and inspection. Any possible damage is typically confined to the case
lugs. If the clutch plates can move freely to engage or release the clutch packs, the transmission
should not be replaced. If the snap ring grooves are not damaged and will securely retain the snap
rings, the transmission should not be replaced. Peening or wear of the edge of the case lugs that
engage the clutch plates is normal and acceptable and not cause for transmission replacement.
4. Remove the control valve body cover (1), control solenoid (w/body and TCM) valve assembly
(15) and filter plate assembly (16). 5. Inspect the filter plate assembly (16) for the presence of
metallic debris on the screens.
- If there is no debris on the screens, the pump fluid filter was effective and there is no debris in the
pump or torque converter. Therefore the pump, torque converter and valve body do not need to be
replaced. The transmission should be repaired.
- If there is debris on the screens, the pump and torque converter should be inspected further.
Refer to SI procedure Transmission Fluid Pump Cleaning and Inspection for the pump. Refer to SI
procedure Torque converter Diagnosis for the section Torque Converter Replacement Guide.
- Fine metal particles that you cannot feel (traces of metal flakes/gray color to the fluid) are not
reasons to replace the torque converter.
- Metal chips/debris that you can feel or that are found in the converter, or when flushing the cooler
and cooler lines, indicate the torque converter should be replaced.
6. The valve body must be disassembled and cleaned, refer to the latest version of Corporate
Bulletin Number 08-07-30-005 for direction. 7. The transmission case halves must be separated,
internal components removed and all parts thoroughly cleaned. Be sure to clean the speed
sensors,
both input (ISS) and output (OSS). These sensors are magnetic and will attach and hold any
ferrous material. Failure to clean these sensors may result in DTCs. A new pump fluid filter must be
installed.
Notice
The front differential carrier assembly (31) teeth are marked with notches to identify gear ratio (see
picture above). Do not confuse these marks with
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-07-30-012B > Mar >
11 > A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9916
tooth damage. Do not replace the gear for this condition.
Important 2007-2008 applications - when assembling these transmissions, inspect the control valve
channel upper plate (301) to make sure that it contains the slot as indicated above. Plates installed
that do not include this slot may result in DTCs.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 09-07-30-012B > Mar >
11 > A/T - No Reverse/3rd or 5th Gear/MIL ON/DTC P0776 > Page 9917
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May >
08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 9925
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 9926
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 9927
Transmission Control Module (TCM) X3 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Page 9928
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9931
7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9932
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9933
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9934
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Sensors and Switches A/T/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9935
1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9936
5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Sensors and Switches
A/T/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9937
the correct software and calibrations, DTC P0602 will be erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Testing and
Inspection/Component Tests and General Diagnostics/AF33-5 - Automatic Transaxle/Transmission
Adaptive Learn and Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic
Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Transmission Fluid Level Indicator Replacement
Removal Procedure
1. Clean any dirt or debris away from the transaxle fluid plug/level indicator area.
2. Remove the transaxle fluid level indicator bolt from the transaxle. 3. Remove the transaxle fluid
level indicator from the transaxle. 4. Wipe away any transaxle fluid from the fluid level indicator.
Installation Procedure
1. Install the transaxle fluid level indicator onto the transaxle.
Notice: Refer to Fastener Notice .
2. Install the transaxle fluid level indicator bolt onto the transaxle.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information
Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 9945
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
AF33-5 - Automatic Transaxle
Complete Overhaul ..............................................................................................................................
....................................................... 7.8L (8.2 Quarts) Remove Drain Plug and Fill .............................
...................................................................................................................................... 4.06L (4.29
Quarts)
6T70/6T75 - Automatic Transmission
Valve Body Cover Removal
..........................................................................................................................................................
5.0-7.0L (5.3-7.4 Quarts) Overhaul .....................................................................................................
.................................................................................... 7.0-9.0L (7.4-9.5 Quarts) Fluid Change- Drain
Plug
..............................................................................................................................................................
4.0-6.0L (4.2-6.3 Quarts)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Specifications > Capacity Specifications > Page 9948
Fluid - A/T: Fluid Type Specifications
AUTOMATIC TRANSMISSION FLUID
5-Speed Automatic Transmission Use only T-IV Automatic Transmission Fluid (GM Part No. U.S.
88900925, in Canada 22689186).
NOTICE: Use of the incorrect automatic transaxle fluid may damage your vehicle, and the
damages may not be covered by your warranty.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Testing and Inspection > AF33-5 Transmission Fluid Checking Procedure
Fluid - A/T: Testing and Inspection AF33-5 Transmission Fluid Checking Procedure
Transmission Fluid Check
Description
Inspection of the transaxle fluid level, correct type of fluid, and the condition of the fluid for accurate
operation of the transaxle.
Procedure
Important: Routine inspection of the transaxle fluid is not required. Transaxle fluid inspection is only
required if there is a symptom indicating a concern with the fluid.
1. Park the vehicle on a flat level surface. 2. Operate the vehicle in order for the transmission fluid
temperature to reach the normal operating range.
Transaxle normal temperature: 60-70 degrees C (140-158 degrees F)
3. With the engine at idle, manual shift through all transaxle ranges and return to the PARK
position. Leave the engine idling. 4. Clean any dirt or debris away from the area of the transaxle
fluid level indicator. 5. Remove the transaxle fluid level indicator bolt (1) from the transaxle. 6.
Remove the transaxle fluid level indicator (2). 7. Wipe away any transaxle fluid from the indicator.
8. Insert the indicator into the transaxle until fully seated.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Testing and Inspection > AF33-5 Transmission Fluid Checking Procedure > Page 9951
Important: Inspecting transaxle fluid level when not at normal temperature can give an incorrect
measurement. The transaxle fluid expands when warm.
9. Remove the indicator and inspect the level and the condition of the oil on the indicator:
* Transmission fluid level at normal operating temperature (1)
* Transmission fluid level if cold (2)
10. If the fluid level is incorrect inspect for the following conditions:
* Fluid below level, inspect for a leak. Refer to Fluid Leak Diagnosis (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/AF33-5 - Automatic Transaxle/Fluid Leak
Diagnosis) or Automatic Transmission Fluid Leaks (See: Testing and Inspection/Symptom Related
Diagnostic Procedures/AF33-5 - Automatic Transaxle/Automatic Transmission Fluid Leaks) .
* Fluid above level, inspect for contamination of the fluid.
Important: The tranaxle uses T-IV fluid, GM P/N 88900925 (Canadian P/N 22689186). The fluid is
normally red in color. The oil may darken in color with more miles on a vehicle.
11. Inspect the condition of the fluid for the following conditions:
* Excessively dirty with particles in the fluid
- If there are no drivability concerns, replace the fluid. Refer to Transmission Fluid Replacement
(See: Service and Repair/Removal and Replacement) .
- If drivability concerns are present disassemble and inspect for a cause.
* Burnt smell
- Inspect for the correct fluid. Refer to Fluid Capacity Specifications (See: Specifications/Capacity
Specifications/AF33-5 - Automatic Transaxle) .
- Inspect for conditions that may of cause overheating of the transmission fluid. Refer to
Transmission Overheats (See: Testing and Inspection/Symptom Related Diagnostic
Procedures/AF33-5 - Automatic Transaxle/Transmission Overheats) .
- If there are no drivability concerns, replace the fluid. Refer to Transmission Fluid Replacement
(See: Service and Repair/Removal and Replacement) .
- If drivability concerns are present disassemble and inspect for cause.
- Inspect the transmission oil cooler system for functioning properly. Refer to Transmission Fluid
Cooler Flushing and Flow Test (See: Testing and Inspection/Component Tests and General
Diagnostics/AF33-5 - Automatic Transaxle/Transmission Fluid Cooler Flushing and Flow Test) .
* Black in color
- Disassemble the transaxle and inspect for components that may have over heated.
- Inspect the transmission oil cooler system for functioning properly. Refer to Transmission Fluid
Cooler Flushing and Flow Test (See: Testing and Inspection/Component Tests and General
Diagnostics/AF33-5 - Automatic Transaxle/Transmission Fluid Cooler Flushing and Flow Test) .
* Milky or white tint in color from coolant or water
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Testing and Inspection > AF33-5 Transmission Fluid Checking Procedure > Page 9952
- Inspect for failure of the transaxle oil cooler. Refer to Engine Coolant/Water in Transmission (See:
Testing and Inspection/Symptom Related Diagnostic Procedures/AF33-5 - Automatic
Transaxle/Engine Coolant/Water in Transmission) .
- Inspect for missing or improperly routed vent hose.
- Inspect for missing fill plug.
12. Install the fluid level indicator.
Notice: Refer to Fastener Notice .
13. Install the fluid indicator bolt.
Tighten the fluid indicator bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Testing and Inspection > AF33-5 Transmission Fluid Checking Procedure > Page 9953
Fluid - A/T: Testing and Inspection 6T70/6T75 Transmission Fluid Checking Procedure
Transmission Fluid Check
This procedure checks both the transmission fluid level, as well as the condition of the fluid itself.
Notice: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in
transmission internal damage.
Important: Ensure the transmission has enough fluid in it to safely start the vehicle without
damaging the transmission. With the vehicle off there must be at least enough fluid to wet the end
of the dipstick bullet. This will ensure that there is enough fluid in the sump to fill the components
once the vehicle is started.
Level Checking Procedure
1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK
(P). 2. Start the engine. 3. Depress the brake pedal and move the shift lever through each gear
range, pausing for about 3 seconds in each range. Then move the shift lever
back to PARK (P).
4. Allow the engine to idle 500-800 rpm for at least 1 minute. Release the brake pedal. 5. Keep the
engine running and observe the transmission fluid temperature (TFT) using the Driver Information
Center or a scan tool.
Important: If the fluid temperature is below the specified range, perform the following procedure to
raise the fluid temperature to the specified range.
6. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or
operate the vehicle until the appropriate TFT is
reached. Drive the vehicle in second gear until the fluid temperature is within the specified range.
Important: Check the transmission fluid level when the TFT is between 180°F and 200°F (82°C and
93°C). The fluid level rises as fluid temperature increases, so it is important to ensure the
transmission fluid temperature is within range.
7. Remove the dipstick and wipe it with a clean rag or paper towel. 8. Inspect the fluid color. The
fluid should be red or dark brown.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal
particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces
and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the
transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair
the oil cooler, and flush the cooler lines.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine
Coolant/Water in Transmission) .
9. Install the dipstick and tighten. Wait three seconds and then remove it again.
Important: Always check the fluid level at least twice. Consistent readings are important to
maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent
assembly to ensure it is clean and unclogged.
10. Check both sides of the dipstick and read the lower level.
Important: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within
the crosshatch band is acceptable.
11. Install and remove the dipstick again to verify the reading. 12. If the fluid level is not within the
crosshatch band, and the transmission temperature is between 180°F and 200°F (82°C and 93°C),
add or dranin
fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only
enough fluid to bring the level into the crosshatch band. Important: Do not add more than one pint
(0.5L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take
much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid
level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic Transmission/Fluid
Leak Diagnosis) .
13. If the fluid level is in the acceptable range, install the dipstick. 14. If the fluid was changed, reset
the transmission oil life monitor if applicable.
Fluid Condition Inspection
* Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal
use, and does not always indicate contamination.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Testing and Inspection > AF33-5 Transmission Fluid Checking Procedure > Page 9954
Important: Fluid that is very dark or black and has a burnt odor usually indicates contamination or
overheating.
* If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal
particles or other debris which may indicate transmission damage. Refer to Road Test (See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/6T70/6T75 - Automatic
Transmission) to verify transmission operation. Change the transmission fluid if no other conditions
are found.
* Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or
water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and
Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine
Coolant/Water in Transmission) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Fluid - A/T: Service and Repair 6T70/6T75 - Automatic Transmission
Transmission Fluid Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9957
Fluid - A/T: Service and Repair AF33-5 - Automatic Transaxle
Transmission Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the drain
plug and drain fluid. Allow at least 5 minutes for the fluid to drain completely. 3. Remove the gasket
from the drain plug and discard.
Installation Procedure
1. Install the new gasket on the drain plug.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug.
Tighten the drain plug to 40 N.m (30 lb ft).
3. Make sure vehicle is level . 4. Remove the fluid level indicator located behind the front transaxle
mount. Refer to Transmission Fluid Level Indicator Replacement (See:
Automatic Transmission Dipstick - Dipstick Tube/Service and Repair) .
Notice: Do not remove the 3rd gear anchor band bolt located on top of the transmission for
checking fluid or adding fluid. Removing the bolt will dislocate internal components and require the
transmission to be removed from the vehicle and disassembled for repair.
Important: Dexron(R)III automatic transmission fluid is not compatible with this transaxle. If
Dexron(R)III ATF is used, transaxle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 9958
failure will result. Refer to Sealers, Adhesives, and Lubricants (See: Specifications/Fluid Type
Specifications) .
5. Add approximately 3.1 L (3.3 Qt) of GM T-IV fluid to the transaxle , using the fluid level indicator
location.
Important: If the check is necessary at a low oil temperature of 30-40°C (86-104°F), perform check
using the COLD range on the level gage. However, the fluid must be re-checked at the proper fluid
temperature.
6. Start engine and operate vehicle until transaxle fluid temperature reaches 60-70°C (140-158°F).
7. Apply parking brake. 8. Depress brake pedal and move shift lever slowly through all gear ranges
from park (P) to low (L), pausing for about 3 seconds in each range.
Return shift lever to park (P) range at idle condition.
9. Pull level gauge out again and check if fluid level is within the HOT range.
10. If fluid is not within the correct level, adjust accordingly:
1. If fluid is below the HOT range, add enough to bring it up to the correct level. 2. If fluid is above
HOT range, drain excess fluid.
11. Install the fluid level indicator. Refer to Transmission Fluid Level Indicator Replacement (See:
Automatic Transmission Dipstick - Dipstick
Tube/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting
Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line
Fitting
INFORMATION
Bulletin No.: 04-07-30-017B
Date: November 25, 2008
Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler
Fitting and Torque Converter Drain Back Check Ball Change
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks
with one of the HYDRA-MATIC(R) Automatic Transmissions shown above.
Supercede:
This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin
Number 04-07-30-017A (Section 07 - Transmission/Transaxle).
Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings
have changed and are not interchangeable with past models. The technician may find that when
replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the
transmission.
A change to the transmission cooler line fittings was implemented in production on February 1,
2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler
line fittings with the longer lead in pilot will not fit on models built before February 1, 2004.
The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2)
(3/8-18 NPSF w/check ball & 1/4-18 NPSF).
If the transmission cooler lines will not connect, then replace them with the following cooler line
fittings as appropriate with the older, shorter lead in pilot design:
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N
20793004.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second
design P/N 15264588.
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N
20793005.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second
design P/N 15264589.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page
9963
The torque specification has changed for the fittings to case. The torque has changed from 38 Nm
(28 lb ft) to 32 Nm (23 lb ft).
Tighten
Tighten the new cooler fittings to 32 Nm (23 lb ft).
The converter drain back check ball (420C) has been removed from the cooler line fitting and is
now located in the channel plate.
If you get a concern of no movement in the morning or after sitting for several hours, the cooler
check ball should be inspected.
The best way to determine where the check ball is located is to look at the cooler line fittings. The
old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check
ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler
check ball.
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > AF33-5 - Automatic Transaxle
Fluid Line/Hose: Service and Repair AF33-5 - Automatic Transaxle
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.
Installation Procedure
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
* Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9966
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears
through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining
ring moves freely in the fitting slots.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9967
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9968
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with the recommended transmission fluid. Refer to Sealers, Adhesives, and Lubricants
(See:
Specifications/Fluid Type Specifications) and Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/AF33-5 - Automatic Transaxle/Transmission
Fluid Check) .
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill) .
2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: ) .
Important: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the
same time other wise the transaxle oil cooler will fall inside the radiator end tank.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9969
3. Remove the oil cooler fitting from the radiator.
Installation Procedure
1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary.
Notice: Refer to Fastener Notice .
Important: The correct thread engagement is critical. Cross-threaded fittings can achieve proper
tightness and still leak.
2. Install the oil cooler fitting to the radiator.
Tighten the fittings to 38 N.m (28 lb ft).
3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: ) .
4. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill) .
5. Adjust the transmission fluid level. Refer to Sealers, Adhesives, and Lubricants (See:
Specifications/Fluid Type Specifications) and Transmission
Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/AF33-5 Automatic Transaxle/Transmission Fluid Check) .
6. Inspect for fluid leaks.
Oil Cooler Hose/Pipe Replacement
Oil Cooler Hose/Pipe Replacement
Removal Procedure
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid
personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the
opposite end from which the components are being removed.
1. Position the vehicle on a hoist and raise the hood. 2. Place a drain pan or suitable container
under the vehicle.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9970
3. Disconnect the upper transaxle oil cooler line from the radiator. 4. Raise the vehicle. Refer to
Lifting and Jacking the Vehicle . 5. Disconnect the lower transaxle oil cooler line.
6. Disengage the transaxle cooler lines from the fan shroud.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9971
7. Remove the transaxle cooler line assembly nut (2) from the transaxle. 8. Remove the transaxle
cooler lines (1) from the vehicle. 9. Replace the transaxle oil cooler pipe seals. Refer to the Fluid
Cooler Pipe Seal Replacement (See: ) .
Installation Procedure
1. Install the transaxle oil cooler lines into the vehicle. 2. Install the transaxle oil cooler line
assembly (1) to the transaxle.
Notice: Refer to Fastener Notice .
3. Install the transaxle oil cooler line assembly nut (2).
Tighten the transaxle oil cooler lines to 9 N.m (80 lb in).
4. Connect the lower transaxle oil cooler line to the radiator.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9972
5. Engage the transaxle oil cooler lines with the fan shroud by snapping in place. 6. Lower the
vehicle.
7. Connect the upper transaxle oil cooler line to the radiator.
Important: DEXRON(R) VI automatic transmission fluid is not compatible with this transaxle. If
DEXRON(R) VI ATF is used, transaxle failure will result. This transaxle uses GM T-IV fluid P/N
88900925.
8. Add fluid to the transaxle. Refer to the Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General
Diagnostics/AF33-5 - Automatic Transaxle/Transmission Fluid Check) .
9. Start the engine a check for leaks.
Fluid Cooler Pipe Seal Replacement
Fluid Cooler Pipe Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9973
Tools Required
* J 41239-1A Cooler Line Seal Installer
* J 45201 Cooler Line Seal Remover
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid
personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the
opposite end from which the components are being removed.
2. Place a drain pan or suitable container under the vehicle.
3. Remove the transaxle oil cooler line assembly nut from the transaxle. 4. Disconnect the
transaxle oil cooler lines from the vehicle.
Important: Ensure that the J 45201 is fully seated into the transaxle seal bore.
5. Insert the collet piece (2) of the J 45201 into the cooler line seal. 6. Insert the forcing screw piece
(1) of the J 45201 into the collet (2). 7. Tighten the forcing screw (1) until snug.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9974
8. Thread the collar piece (1) of the J 45201 onto the collet (3) until snug.
9. Turn the collar clockwise in order to remove the cooler line seal (87).
10. Discard the seal (87). 11. Clean the case bores for the cooler line seals.
Installation Procedure
1. Insert a new transaxle cooler line seal into the case bore.
2. Remove the nub from the J 41239-1A .
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9975
3. Install the nub of the J 41239-1A on the transaxle cooler line seal. 4. Tap the new transaxle
cooler line seal into the case bore.
5. Install the transaxle oil cooler line assembly to the transaxle.
Notice: Refer to Fastener Notice .
6. Install the transaxle oil cooler line assembly nut.
Tighten the transaxle cooler line retaining nut to 9 N.m (80 lb in).
7. Lower the vehicle.
Important: DEXRON(R) VI automatic transmission fluid is not compatible with this transaxle. If
DEXRON(R) VI ATF is used, transaxle failure will result. This transaxle uses GM T-IV fluid P/N
88900925.
8. Add fluid to the transaxle. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General Diagnostics/AF33-5 Automatic Transaxle/Transmission Fluid Check) procedure.
9. Start the engine and check for leaks.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9976
Fluid Line/Hose: Service and Repair 6T70/6T75 - Automatic Transmission
Transmission Fluid Cooler Inlet Hose Replacement
Transmission Fluid Cooler Inlet Hose Replacement
Transmission Fluid Cooler Outlet Hose Replacement
Transmission Fluid Cooler Outlet Hose Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9977
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Transmission Fluid Cooler Pipe Connector Replacement - Radiator
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill) .
2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect
Fitting Disconnection and Connection (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9978
Important: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the
same time other wise the transaxle oil cooler will fall inside the radiator end tank.
3. Remove the oil cooler fitting from the radiator.
Installation Procedure
1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary.
Notice: Refer to Fastener Notice .
Important: The correct thread engagement is critical. Cross-threaded fittings can achieve proper
tightness and still leak.
2. Install the oil cooler fitting to the radiator.
Tighten the fittings to 38 N.m (28 lb ft).
3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting
Disconnection and Connection (See: ) .
4. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill) .
5. Adjust the transmission fluid level. 6. Inspect for fluid leaks.
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9979
Removal Procedure
Important: Perform the following procedure when removing the retaining rings and cooler lines from
the quick connect fittings located on the radiator and/or the transmission.
1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm
(2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting
until the retaining ring is out of position and can be completely removed.
3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.
Installation Procedure
Important: *
Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion.
* Do not reuse any of the existing retaining rings that were removed from the existing quick connect
fittings. Install new retaining rings.
* Ensure the following procedures are performed when installing the new retaining rings onto the
fittings.
1. Install a new retaining ring into the quick connect fitting using the following procedure:
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9980
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears
through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining
ring moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick
connect fitting until a click is either heard or felt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9981
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9.
Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick
connect fitting.
Important: Do not manually depress the retaining clip when installing the plastic cap.
10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
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Component Information > Service and Repair > AF33-5 - Automatic Transaxle > Page 9982
14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the
proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check (See:
Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic
Transmission/Transmission Fluid Check) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications > AF33-5 - Automatic Transaxle
Fluid Pan: Specifications AF33-5 - Automatic Transaxle
Control Valve Body Cover Tighten the 9 control valve body cover bolts in sequence. Tighten the
control valve body cover bolts to
............................................................................................................................................ 13 N.m
(10 lb ft).
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Component Information > Specifications > AF33-5 - Automatic Transaxle > Page 9987
Fluid Pan: Specifications 6T70/6T75 - Automatic Transmission
Control Valve Body Cover Tighten Bolt M6 x 30 (QTY:12) in sequence to
........................................................................................................................................... 12 Nm (9
lb ft) Tighten Stud M6 x 30 (QTY:2) in sequence to
............................................................................................................................................. 12 Nm (9
lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure
Sensor/Switch, A/T > Component Information > Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
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Sensor/Switch, A/T > Component Information > Diagrams > Page 9991
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lateral Acceleration
Sensor, A/T > Component Information > Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
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Sensor, A/T > Component Information > Locations > Page 9995
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise
INFORMATION
Bulletin No.: 01-07-30-042F
Date: February 05, 2010
Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise
Models:
2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3
2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32,
M70)
Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission.
Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle).
Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin
05-07-30-012.
Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift.
During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift
can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same
torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band
applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in
the transfer case.
This is a normal condition. No repairs should be attempted.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
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Solenoid, A/T > Component Information > Locations > Page 10003
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
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316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
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Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Page 10010
Transmission Control Module (TCM) X3 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Locations > Page 10011
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10014
7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10015
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10016
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10017
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Sensors and Switches A/T/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10018
1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page
10019
5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Sensors and Switches
A/T/Transmission Position Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with
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10020
the correct software and calibrations, DTC P0602 will be erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Testing and
Inspection/Component Tests and General Diagnostics/AF33-5 - Automatic Transaxle/Transmission
Adaptive Learn and Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 09-07-30-006 > Mar > 09
> A/T - Fluid Leak From Torque Converter Housing
Seals and Gaskets: Customer Interest A/T - Fluid Leak From Torque Converter Housing
TECHNICAL
Bulletin No.: 09-07-30-006
Date: March 09, 2009
Subject: Transmission Fluid Leak Due to Transmission Converter Housing Seal (Inspect with Dye
and Black Light, Replace Torque Converter Fluid Seal)
Models: 2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE
Equipped with a 6T70/75 Automatic Transmission (RPO MH2, MH4, MH6, MY9)
Condition
Some customers may comment about an oil leak. Upon further investigation, the technician may
find a transmission oil leak at the transmission converter housing or transmission case to housing,
at the gasket, or at the rear lower engine oil pan bolts.
Correction
1. Verify that the transmission has a fluid leak. Refer Fluid Leak Diagnosis Dye and Black Light
Method in SI. Carefully inspect with the black light to check the axle seals. Make sure oil from the
axle seal leak isn't running down the case and ending up on the case to housing split line.
2. Inspect the converter housing to oil pan weep hole and the two lower rear engine oil pan bolts
with a black light. If either location shows leakage with dye, the source is most likely the torque
converter hub seal.
3. Remove the transmission. Refer to Transmission Removal in SI.
4. Once the transmission is removed from the vehicle, inspect with the black light to ensure that the
leak is coming from the torque converter fluid seal. Install a new seal assembly, GM P/N 24249775.
Refer to Torque Converter Fluid Seal Replacement in SI.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-07-30-032E > Sep >
08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 10033
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 09-07-30-006
> Mar > 09 > A/T - Fluid Leak From Torque Converter Housing
Seals and Gaskets: All Technical Service Bulletins A/T - Fluid Leak From Torque Converter
Housing
TECHNICAL
Bulletin No.: 09-07-30-006
Date: March 09, 2009
Subject: Transmission Fluid Leak Due to Transmission Converter Housing Seal (Inspect with Dye
and Black Light, Replace Torque Converter Fluid Seal)
Models: 2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE
Equipped with a 6T70/75 Automatic Transmission (RPO MH2, MH4, MH6, MY9)
Condition
Some customers may comment about an oil leak. Upon further investigation, the technician may
find a transmission oil leak at the transmission converter housing or transmission case to housing,
at the gasket, or at the rear lower engine oil pan bolts.
Correction
1. Verify that the transmission has a fluid leak. Refer Fluid Leak Diagnosis Dye and Black Light
Method in SI. Carefully inspect with the black light to check the axle seals. Make sure oil from the
axle seal leak isn't running down the case and ending up on the case to housing split line.
2. Inspect the converter housing to oil pan weep hole and the two lower rear engine oil pan bolts
with a black light. If either location shows leakage with dye, the source is most likely the torque
converter hub seal.
3. Remove the transmission. Refer to Transmission Removal in SI.
4. Once the transmission is removed from the vehicle, inspect with the black light to ensure that the
leak is coming from the torque converter fluid seal. Install a new seal assembly, GM P/N 24249775.
Refer to Torque Converter Fluid Seal Replacement in SI.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent
Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 10043
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10044
Seals and Gaskets: By Symptom
Technical Service Bulletin # 09-07-30-006 Date: 090309
A/T - Fluid Leak From Torque Converter Housing
TECHNICAL
Bulletin No.: 09-07-30-006
Date: March 09, 2009
Subject: Transmission Fluid Leak Due to Transmission Converter Housing Seal (Inspect with Dye
and Black Light, Replace Torque Converter Fluid Seal)
Models: 2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE
Equipped with a 6T70/75 Automatic Transmission (RPO MH2, MH4, MH6, MY9)
Condition
Some customers may comment about an oil leak. Upon further investigation, the technician may
find a transmission oil leak at the transmission converter housing or transmission case to housing,
at the gasket, or at the rear lower engine oil pan bolts.
Correction
1. Verify that the transmission has a fluid leak. Refer Fluid Leak Diagnosis Dye and Black Light
Method in SI. Carefully inspect with the black light to check the axle seals. Make sure oil from the
axle seal leak isn't running down the case and ending up on the case to housing split line.
2. Inspect the converter housing to oil pan weep hole and the two lower rear engine oil pan bolts
with a black light. If either location shows leakage with dye, the source is most likely the torque
converter hub seal.
3. Remove the transmission. Refer to Transmission Removal in SI.
4. Once the transmission is removed from the vehicle, inspect with the black light to ensure that the
leak is coming from the torque converter fluid seal. Install a new seal assembly, GM P/N 24249775.
Refer to Torque Converter Fluid Seal Replacement in SI.
Parts Information
Warranty Information
Disclaimer
Technical Service Bulletin # 01-07-30-032E Date: 080929
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10045
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10046
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 09-07-30-006 Date: 090309
A/T - Fluid Leak From Torque Converter Housing
TECHNICAL
Bulletin No.: 09-07-30-006
Date: March 09, 2009
Subject: Transmission Fluid Leak Due to Transmission Converter Housing Seal (Inspect with Dye
and Black Light, Replace Torque Converter Fluid Seal)
Models: 2008-2009 Buick Enclave 2008-2009 Chevrolet Equinox, Malibu 2009 Chevrolet Traverse
2007-2009 GMC Acadia 2007-2009 Pontiac G6 2008-2009 Pontiac Torrent 2007-2009 Saturn
AURA, OUTLOOK 2008-2009 Saturn VUE
Equipped with a 6T70/75 Automatic Transmission (RPO MH2, MH4, MH6, MY9)
Condition
Some customers may comment about an oil leak. Upon further investigation, the technician may
find a transmission oil leak at the transmission converter housing or transmission case to housing,
at the gasket, or at the rear lower engine oil pan bolts.
Correction
1. Verify that the transmission has a fluid leak. Refer Fluid Leak Diagnosis Dye and Black Light
Method in SI. Carefully inspect with the black light to check the axle seals. Make sure oil from the
axle seal leak isn't running down the case and ending up on the case to housing split line.
2. Inspect the converter housing to oil pan weep hole and the two lower rear engine oil pan bolts
with a black light. If either location shows leakage with dye, the source is most likely the torque
converter hub seal.
3. Remove the transmission. Refer to Transmission Removal in SI.
4. Once the transmission is removed from the vehicle, inspect with the black light to ensure that the
leak is coming from the torque converter fluid seal. Install a new seal assembly, GM P/N 24249775.
Refer to Torque Converter Fluid Seal Replacement in SI.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10047
Warranty Information
Disclaimer
Technical Service Bulletin # 01-07-30-032E Date: 080929
A/T - 4T65E Fluid Leaking From A/T Vent
TECHNICAL
Bulletin No.: 01-07-30-032E
Date: September 29, 2008
Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover
(Channel Plate) Gasket)
Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn)
with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76)
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak.
Cause
This condition may be caused by an improperly torqued channel plate gasket.
Correction
To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to
Unit Repair publication in SI of the appropriate vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10048
being serviced.
Visual inspection of the upper gasket (1) will reveal damage at the referenced area.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission
Seals and Gaskets: Service and Repair AF33-5 - Automatic Transmission
Front Axle Shaft Seal Replacement - Left
Front Axle Shaft Seal Replacement (Left)
Tools Required
* J 44809 Output Shaft Seal Installer
* J 45000 Seal Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Place a drain pan
under the transaxle to catch any spilled transaxle fluid. 3. Remove the left front axle shaft. Refer to
Front Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
4. Using the J 45000 , remove the axle seal from the transaxle and discard. 5. Clean the seal bore
in the transaxle housing.
Installation Procedure
1. Using the J 44809 , install the left axle seal into the transaxle . 2. Install the left front axle shaft.
Refer to Front Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
3. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10051
Important: Dextron(R)III automatic transmission fluid is not compatible with this transaxle. If
Dextron(R)III ATF is used, transaxle failure will result. This transaxle uses GM T-IV fluid GM P/N
88900925.
4. Inspect the transaxle fluid level. Refer to Transmission Fluid Check (See: Testing and
Inspection/Component Tests and General
Diagnostics/AF33-5 - Automatic Transaxle/Transmission Fluid Check) .
Front Axle Shaft Seal Replacement (Right)
Front Axle Shaft Seal Replacement (Right)
Tools Required
* J 45000 Seal Remover
* J 45187 Differential Output Shaft Oil Seal Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Place a drain pan
under the transaxle to catch any spilled transaxle fluid. 3. Remove the right front wheel drive shaft.
Refer to Front Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
4. If equipped with an axle seal dust cover, discard it and do not replace it.
5. Using the J 45000 remove the right drive axle seal from the transaxle. 6. Clean the seal bore in
the transaxle housing.
Installation Procedure
1. Using the J 45187 , install the right drive axle seal onto the transaxle. 2. Install the right front
wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10052
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
3. Lower the vehicle.
Important: Dextron(R)III automatic transmission fluid is not compatible with this transaxle. If
Dextron(R)III ATF is used, transaxle failure will result. This transaxle uses GM T-IV fluid GM P/N
88900925.
4. Inspect the transaxle fluid level. Refer to Automatic Transmission Controls Schematics (See:
Transmission Control Systems/Diagrams/Electrical
Diagrams) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10053
Seals and Gaskets: Service and Repair 6T70/6T75 - Automatic Transmission
Front Wheel Drive Shaft Oil Seal Replacement - Left
Front Wheel Drive Shaft Oil Seal Replacement - Left Side
Front Wheel Drive Shaft Oil Seal Replacement - Right
Front Wheel Drive Shaft Oil Seal Replacement - Right Side (AWD)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10054
Input Speed Sensor Seal Replacement
Input Speed Sensor Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10055
Manual Shift Shaft and Seal Replacement
Manual Shift Shaft and Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T
> System Information > Service and Repair > AF33-5 - Automatic Transmission > Page 10056
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10061
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations > Page 10065
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views > Page 10073
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views > Page 10074
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic
Component Views > Page 10075
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10078
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10079
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10084
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10085
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10086
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10087
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10088
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page
10089
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10090
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10091
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10092
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10095
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10096
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10097
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10098
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10099
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
> Page 10105
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
> Page 10106
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
> Page 10107
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10108
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Shift Lever Components
Below The Shifter
1 - Instrument Panel Trim 2 - Console Arm Rest 3 - Cigar Lighter 4 - Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Shift Interlock Solenoid > Component Information > Locations > Page 10113
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > AF33-5 - Automatic Transaxle
Shift Solenoid: Specifications AF33-5 - Automatic Transaxle
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > AF33-5 - Automatic Transaxle > Page 10118
Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission
Shift Solenoid Valve State and Gear Ratio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > AF33-5 - Automatic Transaxle
Shift Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10121
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10122
Shift Solenoid: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10123
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10126
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10127
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10128
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10129
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10167
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Component Information > Diagrams > Diagram Information and Instructions > Page 10168
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10169
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10170
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10171
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10172
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Component Information > Diagrams > Diagram Information and Instructions > Page 10173
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10177
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10180
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10181
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 10182
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10183
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10184
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10185
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10186
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10189
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10190
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10191
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10196
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10197
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10200
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10201
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10210
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Component Information > Diagrams > Diagram Information and Instructions > Page 10215
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10217
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10218
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10219
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10220
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10221
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10222
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10223
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10224
Shift Solenoid: Connector Views
Component Connector End Views - Continued
Shift Solenoid 1 (AF33-5)
Shift Solenoid 2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10225
Shift Solenoid 3 (AF33-5)
Shift Solenoid 4 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10226
Shift Solenoid 5 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10227
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 10228
Shift Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 10229
Shift Solenoid: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly. 7.
Remove the 2 control valve body bolts (4) M6 x 65.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 10230
8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6
x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 10231
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 10232
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and
Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Shifter A/T: Service and Repair 6T70/6T75 - Automatic Transmission
Transmission Control Lever Knob Replacement
Transmission Control Lever Knob Replacement
Transmission Control Bracket Replacement
Transmission Control Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10237
Transmission Control Replacement
Transmission Control Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10238
Automatic Transmission Range Selector Lever Replacement
Automatic Transmission Range Selector Lever Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10239
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10240
Shifter A/T: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Lever Knob Replacement
Transmission Control Lever Knob Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10241
Transmission Control Replacement
Transmission Control Replacement
Transmission Brace Replacement
Transmission Brace Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10242
2. Remove the transaxle brace to engine oil pan bolts (2). 3. Remove the transaxle brace to
transaxle bolt (1). 4. Remove the transaxle brace (3).
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install the transaxle brace (3). 2. Install the transaxle brace bolts (1, 2).
Tighten the bolts to 50 N.m (37 lb ft).
3. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle
Shift Cable: Adjustments AF33-5 - Automatic Transaxle
Shift Control Cable Adjustment
1. Position the shift lever in PARK.
2. Release the shift control cable adjustment lock cover retaining tab (1) on the bottom side.
3. Slide the shift control cable adjustment lock cover (2) forward exposing the adjustment lock. 4.
Carefully squeeze the adjustment lock tabs (1) inward to disengage the adjustment lock.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle > Page 10248
5. Lift the shift control cable adjustment lock (3). 6. The shift control cable (1) and cable end (2) are
free to slide to proper adjustment. Ensure the shift lever and transmission are both in the PARK
position.
7. Depress the shift control cable adjustment lock (1) to lock the adjustment.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle > Page 10249
8. Slide the shift control cable adjustment lock cover (1) over the adjustment lock. 9. Inspect the
operation of the starting system with the shift lever in each position. The engine should only crank
when the lever is in the PARK or
NEUTRAL position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle > Page 10250
Shift Cable: Adjustments 6T70/6T75 - Automatic Transmission
Range Selector Lever Cable Adjustment
1. Position the shift lever in PARK.
2. Release the range selector cable adjustment lock cover retaining tab (1) on the bottom side.
3. Slide the range selector cable adjustment lock cover (2) forward exposing the adjustment lock. 4.
Carefully squeeze the adjustment lock tabs (1) inward to disengage the adjustment lock.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle > Page 10251
5. Lift the range selector cable adjustment lock (3). 6. The range selector cable (1) and cable end
(2) are free to slide to proper adjustment. Ensure the shift lever and transmission are both in the
PARK
position.
7. Depress the range selector cable adjustment lock (1) to lock the adjustment.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Adjustments > AF33-5 - Automatic Transaxle > Page 10252
8. Slide the range selector cable adjustment lock cover (1) over the adjustment lock. 9. Inspect the
operation of the starting system with the shift control lever in each position. The engine should only
crank when the lever is in the
PARK or NEUTRAL position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Shift Cable: Service and Repair 6T70/6T75 - Automatic Transmission
Range Selector Lever Cable Replacement
Range Selector Lever Cable Replacement
Removal Procedure
1. Set the parking brake. 2. Ensure that the shift control range select lever is in the park (P)
position.
3. Disconnect the shift control cable (1) from the transmission range selector lever. 4. Depress the
range selector cable retainer clip tabs (2) and remove the range selector cable from the range
selector cable bracket. 5. Remove the shift control lever knob. Refer to Transmission Control Lever
Knob Replacement (See: Shifter A/T/Service and Repair/6T70/6T75 Automatic Transmission/Transmission Control Lever Knob Replacement) .
6. Remove the center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement . 7.
Remove the console trim plate. Refer to Console Trim Plate Replacement . 8. Remove the right
side console trim panel. Refer to Front Floor Console Side Trim Panel Replacement - Right Side .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10255
9. Disconnect the shift control cable (1) from the shift control range select lever pin.
10. Depress the shift control cable retainer clip tabs and remove the cable (2) from the shift control.
11. Remove the shift control cable grommet from the cowl. 12. Note the shift control cable routing
and remove the shift control cable from the vehicle.
Installation Procedure
Important: Ensure the shift control cable is routed exactly as originally positioned in the vehicle to
avoid coming into contact with potential hazards such as hot, sharp, and moving objects.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10256
1. Secure the shift control cable grommet by pressing the cable into the pass-thru hole in the cowl.
2. Ensure that the shift control range select lever is in the park (P) position.
3. Install the shift control cable (2) to the shift control. 4. Install the shift control cable (1) onto the
shift control range select lever pin. 5. Install the right side console trim panel. Refer to Front Floor
Console Side Trim Panel Replacement - Right Side . 6. Install the console trim plate. Refer to
Console Trim Plate Replacement . 7. Install the center trim bezel. Refer to Instrument Panel
Accessory Bezel Replacement . 8. Install the shift control lever knob. Refer to Transmission Control
Lever Knob Replacement (See: Shifter A/T/Service and Repair/6T70/6T75 Automatic Transmission/Transmission Control Lever Knob Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10257
9. Install the shift control cable (2) to the range selector cable bracket. Ensure the range selector
cable retaining tabs fully engage the range selector
cable bracket.
10. Connect the range selector cable (1) to the transmission range selector lever. 11. Adjust the
range selector cable. Refer to Shift Control Cable Adjustment (See: Adjustments) . 12. Release the
parking brake.
Range Selector Lever Cable Bracket Replacement
Range Selector Lever Cable Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10258
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10259
Shift Cable: Service and Repair AF33-5 - Automatic Transaxle
Shift Control Cable Replacement
Shift Control Cable Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Set the parking brake. 2. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR
Disabling and Enabling . 3. Remove the battery tray. Refer to Battery Tray Replacement . 4.
Ensure that the shift control range select lever is in the park (P) position.
5. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 6. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3). 7. Remove the shift control lever knob. Refer to Transmission
Control Lever Knob Replacement (See: Shifter A/T/Service and Repair/AF33-5 Automatic Transaxle/Transmission Control Lever Knob Replacement) .
8. Remove the center trim bezel. Refer to Instrument Panel Accessory Bezel Replacement . 9.
Remove the console trim plate. Refer to Console Trim Plate Replacement .
10. Remove the right side console trim panel. Refer to Front Floor Console Side Trim Panel
Replacement - Right Side .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10260
11. Using the J 36346 , disconnect the shift control cable from the shift control range select lever
pin. 12. Depress the shift control cable retainer clip tabs and remove the cable from the shift
control.
13. Remove the shift control cable grommet from the cowl. 14. Note the shift control cable routing
and remove the shift control cable from the vehicle.
Installation Procedure
Important: Ensure the shift control cable is routed exactly as originally positioned in the vehicle to
avoid coming into contact with potential hazards such as hot, sharp, and moving objects.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10261
1. Secure the shift control cable grommet by pressing the cable into the pass-thru hole in the cowl.
2. Ensure that the shift control range select lever is in the park (P) position.
3. Install the shift control cable to the shift control. 4. Install the shift control cable onto the shift
control range select lever pin. 5. Install the right side console trim panel. Refer to Front Floor
Console Side Trim Panel Replacement - Right Side . 6. Install the console trim plate. Refer to
Console Trim Plate Replacement . 7. Install the center trim bezel. Refer to Instrument Panel
Accessory Bezel Replacement . 8. Install the shift control lever knob. Refer to Transmission Control
Lever Knob Replacement (See: Shifter A/T/Service and Repair/AF33-5 Automatic Transaxle/Transmission Control Lever Knob Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10262
9. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
10. Connect the shift control cable (1) to the transaxle range switch lever (4). 11. Adjust the shift
control cable. Refer to Shift Control Cable Adjustment (See: Adjustments) . 12. Install the battery
tray. Refer to Battery Tray Replacement . 13. Enable the supplemental inflatable restraint (SIR)
system. Refer to SIR Disabling and Enabling . 14. Release the parking brake.
Shift Control Cable Bracket Replacement
Shift Control Cable Bracket Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10263
2. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 3. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
4. Remove the shift control cable bracket bolts. 5. Remove the shift control cable bracket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Shift Cable, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10264
1. Install the transaxle shift control bracket.
Notice: Refer to Fastener Notice .
2. Install the transaxle shift control bracket.
Tighten the bolts to 25 N.m (18 lb ft).
3. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
4. Connect the shift control cable (1) to the transaxle range switch lever (4). 5. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information
Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information
INFORMATION
Bulletin No.: 01-07-30-010C
Date: May 12, 2008
Subject: Automatic Transmission/Transaxle Torque Converter Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009
and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75)
2009 and Prior Saab 9-7X
with ALL Automatic Transmissions and Transaxles
Supercede:
This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin
Number 01-07-30-010B (Section 07 - Transmission/Transaxle).
The purpose of this bulletin is to help technicians determine when a torque converter should be
replaced. Below is a list of general guidelines to follow.
The converter should NOT be replaced if the following apply:
^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition
(i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical
concern within the torque converter.
^ The fluid has an odor or is discolored but no evidence of metal contamination.
^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is
not harmful to the torque converter.
^ The vehicle has been exposed to high mileage.
^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter
(RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither
the converter nor the front pump assembly should be replaced.
The torque converter should be replaced under any of the following conditions:
^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic
diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the
converter bushing and/or internal 0-ring may be damaged.
^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support
and bearing or metal chips/debris in the converter.
^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines.
^ External leaks in the hub weld area lug weld or closure weld.
^ Converter pilot is broken damaged or fits poorly into the crankshaft.
^ The converter hub is scored or damaged.
^ The transmission oil is contaminated with engine coolant engine oil or water.
^ If excessive end play is found after measuring the converter for proper end play (refer to Service
Manual).
^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit
are worn or damaged. This indicates that the material came from the converter.
^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by
following Converter Vibration Procedures.
^ Blue converter or dark circular ring between lugs. This condition will also require a complete
cleaning of the cooler and a check for adequate flow
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 10269
through the cooler.
^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at
idle. The noise is gone in Neutral and Park.
^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line
Fitting
Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check
Valve/Cooler Line Fitting
INFORMATION
Bulletin No.: 04-07-30-017B
Date: November 25, 2008
Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler
Fitting and Torque Converter Drain Back Check Ball Change
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks
with one of the HYDRA-MATIC(R) Automatic Transmissions shown above.
Supercede:
This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin
Number 04-07-30-017A (Section 07 - Transmission/Transaxle).
Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings
have changed and are not interchangeable with past models. The technician may find that when
replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the
transmission.
A change to the transmission cooler line fittings was implemented in production on February 1,
2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler
line fittings with the longer lead in pilot will not fit on models built before February 1, 2004.
The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2)
(3/8-18 NPSF w/check ball & 1/4-18 NPSF).
If the transmission cooler lines will not connect, then replace them with the following cooler line
fittings as appropriate with the older, shorter lead in pilot design:
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N
20793004.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second
design P/N 15264588.
^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N
20793005.
^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second
design P/N 15264589.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line
Fitting > Page 10274
The torque specification has changed for the fittings to case. The torque has changed from 38 Nm
(28 lb ft) to 32 Nm (23 lb ft).
Tighten
Tighten the new cooler fittings to 32 Nm (23 lb ft).
The converter drain back check ball (420C) has been removed from the cooler line fitting and is
now located in the channel plate.
If you get a concern of no movement in the morning or after sitting for several hours, the cooler
check ball should be inspected.
The best way to determine where the check ball is located is to look at the cooler line fittings. The
old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check
ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler
check ball.
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Torque Converter Clutch Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10279
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10280
Torque Converter Clutch Solenoid: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10281
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10282
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10285
Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10286
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10287
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10288
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10289
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10290
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10291
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10292
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10315
* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10317
View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10338
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10339
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10340
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10341
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10342
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10343
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10344
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10345
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10346
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10347
3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10348
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10349
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10350
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10351
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10352
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10353
2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10354
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10355
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10356
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10357
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10358
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10359
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10360
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10361
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10363
2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10364
View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10365
View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10369
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10370
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10371
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10372
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10373
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10374
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10375
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10376
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10378
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10380
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10381
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10382
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10383
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Lock Up Pressure Control Solenoid (SLU) (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter
Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10384
Torque Converter Clutch Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush
Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush
INFORMATION
Bulletin No.: 02-07-30-052G
Date: March 02, 2011
Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow(R)
Models:
2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010
HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle).
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J
35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and
DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled
through the transmission oil cooling system. High-pressure air is automatically injected into the fluid
stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris.
In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil
cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along
with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles
and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel
has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material
that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum
evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can
be used for verification of flow test results.
Current essential cooler line adapters are used to connect the J 45096 to the automatic
transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and
light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo).
The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership
personnel with a barbed hose connector and rubber hose obtained locally. The
Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different
than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic
transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the
flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the
Vibe's/Wave's/Aveo's transmission fluid.
Notice
Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure.
The required minimum ATF oil flow rate reading is directly related to the supply oil temperature.
Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of
the ATF in the supply vessel.
Helpful Hints for Maintaining the Temperature at or above 18°C (65°F)
Important
- The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It
is recommended to store the J 45096 in an area of the dealership where the room temperature
remains at or above 18°C (65°F) when not in use.
- Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil
dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the
supply reservoir. Inserting a heater will damage the check valve and the subsequent repair
expense would be the dealer's responsibility.
- A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system
flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110
volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a
thermostat to hold a constant temperature.
Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room
where the temperature is maintained at or above 18°C (65°F).
Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J
45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is
maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the
machine on
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 10389
each repair.
With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of
time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the
reservoir.
Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the
reservoir to the rays of the warm sun.
Flush / Flow Test Procedure
Important All labor operations that include removal of the transmission from the vehicle and require
the transmission oil pan or transmission side cover to be removed include labor time to flush the
transmission oil cooler system.
Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the
appropriate procedure.
Important The J 45096 can be used to flush the transmission oil cooler system on an Allison
equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission
Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure.
Machine Displays
After completion of the flush and flow test, the following information is to be recorded on the repair
order. This information is displayed on the Transmission Cooling System Service Tool, J 45096,
Transflow(R) machine when the dial is in the code position.
- Tested flow rate (displayed in Gallons Per Minute (GPM)
- Temperature (displayed is degrees Fahrenheit)
- Cycle number (a number)
- Seven digit Alpha/Numeric flow code (i.e. A10DFB2)
Warranty Information
Important All labor operations that include removal of the transmission from the vehicle include
labor time to flush the transmission oil cooler system.
Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts)
of DEXRON(R)VI transmission fluid. The amount
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 10390
of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the
repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be
shown in the Parts Section of the warranty claim document.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card,
entered in the warranty claim labor operation Flush Code additional field (when available) and
placed in the comments section of the warranty claim. Any repair that requires the technician to
contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent
will request the seven digit flow code and add the information to the PQC case prior to providing
authorization for the warranty claim.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 10391
Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination
Information
INFORMATION
Bulletin No.: 08-07-30-035B
Date: November 01, 2010
Subject: Information on Water or Ethylene Glycol in Transmission Fluid
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission
Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin
Number 08-07-30-035A (Section 07 - Transmission/Transaxle).
Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission
components and will have a negative effect on reliability and durability of these parts. Water or
ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder
during engagement or gear changes, especially during torque converter clutch engagement.
Indications of water in the ATF may include:
- ATF blowing out of the transmission vent tube.
- ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a
strawberry milkshake.
- Visible water in the oil pan.
- A milky white substance inside the pan area.
- Spacer plate gaskets that appear to be glued to the valve body face or case.
- Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not
compressed.
- Rust on internal transmission iron/steel components.
If water in the ATF has been found and the source of the water entry has not been identified, or if a
leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in
the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of
ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be
obtained and the ATF tested to make an accurate decision on the need for radiator replacement.
This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking
and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These
test kits can be obtained from:
Nelco Company
Test kits can be ordered by phone or through the website listed above. Orders are shipped
standard delivery time but can be shipped on a next day delivery basis for an extra charge. One
test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost
of the complete test kit plus shipping charges should be divided by 10 and submitted on the
warranty claim as a net item.
The transmission should be repaired or replaced based on the normal cost comparison procedure.
Important If water or coolant is found in the transmission, the following components MUST be
replaced.
- Replace all of the rubber-type seals.
- Replace all of the composition-faced clutch plates and/or bands.
- Replace all of the nylon parts.
- Replace the torque converter.
- Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
Important The following steps must be completed when repairing or replacing.
Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number
02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096
TransFlow.
- Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler,
A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 10392
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Testing and Inspection
Transmission Mount: Testing and Inspection
Transmission Mount Inspection
Inspection Procedure
Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that
spans the width of the oil pan bottom between the oil pan and the jack support.
Important: Before replacing any transmission mount due to a suspected fluid loss, verify that the
source of the fluid is the mount.
1. Raise the transmission/transaxle in order to relieve tension in the mount. 2. Observe the mount
while raising the transmission/transaxle. Raising the transmission/transaxle removes the weight
from the mount. 3. Replace the mount if it exhibits any of the following conditions:
* The hard rubber surface is covered with heat check cracks.
* The rubber is separated from the outer metal sleeve of the mount.
* The rubber is split through the center of the transmission mount.
* The mount is leaking fluid.
4. When replacing the transmission mounts or brackets, refer to the following procedures:
* Transmission Rear Mount Replacement (See: Service and Repair/AF33-5 - Automatic
Transaxle/Transmission Rear Mount Replacement)
* Transmission Rear Mount Bracket Replacement (See: Service and Repair/AF33-5 - Automatic
Transaxle/Transmission Rear Mount Bracket Replacement)
* Transmission Mount Replacement - Left Side (See: Service and Repair/AF33-5 - Automatic
Transaxle/Transmission Mount Replacement - Left Side)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Mount: Service and Repair 6T70/6T75 - Automatic Transmission
Transmission Mount Bracket Replacement - Rear
Transmission Mount Bracket Replacement - Rear (AWD)
Transmission Mount Bracket Replacement - Left Side
Transmission Mount Bracket Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10401
Transmission Brace Replacement
Transmission Brace Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10402
Transmission Mount Replacement - Left Side
Transmission Mount Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10403
Transmission Front Mount Replacement
Transmission Front Mount Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10404
Transmission Rear Mount Replacement
Transmission Rear Mount Replacement (AWD)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10405
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10406
Transmission Mount: Service and Repair AF33-5 - Automatic Transaxle
Transmission Rear Mount Replacement
Transmission Rear Mount Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove both front
tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service and Repair) .
3. If equipped with AWD, disconnect the stabilizer links from the stabilizer shaft. 4. If equipped with
AWD, swing the stabilizer shaft upwards in order to gain additional clearance.
5. Remove the transmission mount-to-bracket through bolt. 6. Remove the transmission
mount-to-frame bolts. 7. Remove the transmission mount from the vehicle.
Installation Procedure
1. Position the transmission mount to the frame.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10407
Notice: Refer to Fastener Notice .
2. Install the transmission mount-to-frame bolts.
Tighten the bolt to 50 N.m (37 lb ft).
3. Install the transmission mount-to-bracket through bolt, while aligning the transmission mount to
the bracket.
Tighten the bolt to 110 N.m (81 lb ft).
4. If equipped with AWD, lower the stabilizer shaft and connect the stabilizer links .
Tighten the stabilizer link nuts to 65 N.m (48 lb ft).
5. Install both front tires and wheels. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service and Repair) . 6. Lower the vehicle.
Transmission Mount Replacement - Left Side
Transmission Mount Replacement - Left Side
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10408
1. Support the engine. Refer to Engine Support Fixture . 2. Remove the battery tray. Refer to
Battery Tray Replacement .
3. Remove the transmission mount to transmission bolts.
4. Remove the transmission mount to frame rail bolts. 5. Remove the mount from the engine.
Installation Procedure
1. Position the transmission mount on the frame rail.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10409
Notice: Refer to Fastener Notice .
2. Install the transmission mount to frame rail bolts.
Tighten the bolts to 37 N.m (27 lb ft).
3. Install the transmission mount to transmission bolts.
Tighten the bolts to 55 N.m (41 lb ft).
4. Install the battery tray. Refer to Battery Tray Replacement . 5. Remove the engine support. Refer
to Engine Support Fixture .
Transmission Rear Mount Bracket Replacement
Transmission Rear Mount Bracket Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10410
1. Remove the rear transmission mount. Refer to Transmission Rear Mount Replacement (See:
Transmission Rear Mount Replacement) .
2. Disconnect the intermediate steering shaft from the steering gear.
3. Remove the steering gear to frame bolts. 4. Secure the steering gear upward in order to gain
additional clearance.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10411
5. Remove the transmission mount bracket to transmission bolts.
6. Remove the transmission mount bracket from the vehicle.
Installation Procedure
1. Position the transmission mount bracket to the transmission.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10412
Notice: Refer to Fastener Notice .
2. Install the transmission mount bracket to transmission bolts.
Tighten the bolts to 110 N.m (81 lb ft).
3. Lower the steering gear to the frame. 4. Install the steering gear to frame bolts.
Tighten the bolts to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount,
A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10413
5. Install the intermediate steering shaft to the steering gear. 6. Install the intermediate steering
shaft to gear pinch bolt.
Tighten the bolts to 34 N.m (25 lb ft).
7. Install the rear transmission mount. Refer to Transmission Rear Mount Replacement (See:
Transmission Rear Mount Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
10418
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
10419
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Automatic Transmission Electronic Component Views > Page
10420
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10423
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10424
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Service and Repair
Transmission Pressure Test Port: Service and Repair
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10432
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10433
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10434
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10435
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10436
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10437
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 10438
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 10439
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Page 10440
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10443
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10444
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10445
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10446
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10447
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10453
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10454
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > AF33-5 - Automatic Transaxle > Page 10455
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10456
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips
Valve Body: Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips
INFORMATION
Bulletin No.: 01-07-30-036H
Date: January 29, 2009
Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70)
Supercede:
This bulletin is being revised to add the 2009 model year and add details regarding spacer plates.
Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle).
Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve
Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service
Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may
also describe a condition of a second, third or fourth gear start that may have the same causes but
has not set this DTC yet. Below are some tips when diagnosing this DTC:
^ This is a performance code. This means that a mechanical malfunction exists.
^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical
connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set.
^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the
spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is
important to remove the spacer plate and inspect orifice # 29 and the immediate area for the
presence of chips/debris. Also, the transmission case passage directly above this orifice and the
valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003
and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a
bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens
can help to prevent plugging of orifice # 29 caused by small debris or chips.
^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the
2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the
valves, the bore and the valve body passages.
^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer
to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on
parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition.
Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found
to be cracked, broken or leaking.
It is important to also refer to the appropriate Service Manual or Service Information (SI) for further
possible causes of this condition.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10461
Valve Body: Technical Service Bulletins A/T - Valve Body Reconditioning
Bulletin No.: 08-07-30-005A
Date: February 13, 2008
INFORMATION
Subject: HYDRA-MATIC(R) Front Wheel Drive 6T70-E (MH2), 6T75-E (MY9) and All Wheel Drive
6T70-E (MH4), 6T75-E (MH6) Automatic Transmission Control Valve Body Assembly
Reconditioning
Models: 2008 Buick Enclave 2008 Chevrolet Equinox, Malibu 2007-2008 GMC Acadia 2007-2008
Pontiac G6 2008 Pontiac Torrent 2007-2008 Saturn AURA, OUTLOOK 2008 Saturn VUE
with 6T70-E, 6T75-E HYDRA-MATIC(R) Front Wheel Drive Automatic Transmission (RPOs MH2,
MY9) or 6T70-E, 6T75-E HYDRA-MATIC(R) All Wheel Drive Automatic Transmission (RPOs MH4,
MH6)
Supercede:
This bulletin is being updated to add the control valve body upper and lower spacer plate
assembly. Please discard Corporate Bulletin Number 08-07-30-005 (Section 07 Transmission/Transaxle).
The information outlined in this bulletin is designed to provide easy to follow control valve body
reconditioning instructions using the new illustrations to simplify reassembly of the 6T70-E and/or
6T750-E automatic transmission control valve body assembly.
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in
order to dry any transmission components. Lint from the towels can cause component failure.
Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may
damage the component.
Inspection Procedure for Shift Concerns
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10462
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10463
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10464
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10465
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10466
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10467
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10468
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10469
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10470
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10471
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10472
Using the exploded view inspect each bore for freedom of valve(s) movement and evidence of
debris. Pay particular attention to those valves related to the customer's concern. IF VALVE BODY
CLEANING IS NOT REQUIRED, DO NOT DISASSEMBLE THE BORES UNLESS IT IS
NECESSARY TO VERIFY MOVEMENT.
Verify movement of the valves in their normal installed position. Valves may become restricted
during removal or installation. This is normal due to small tolerances between the valves and
bores.
If a valve is restricted and cannot be corrected by cleaning the valve and bore replace the valve
body. Describe the restricted valve on the repair order.
Disassembly/Reassembly for Cleaning Debris
If a valve is restricted by a metal burr from machining that bore remove the valve and burr. Inspect
the movement in the valve's normal position. If no other debris or restrictions are found reassemble
the valve body and install in the transmission.
If the valve body has been contaminated with debris from another transmission component failure
disassemble all bores for complete cleaning of all
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T Control - DTC P0756 Diagnostic Tips > Page 10473
valve body components. Keeping individual bore parts separated will make reassembly easier. Use
the illustrations shown above for positive identification and location of individual parts.
Using GM Brake Clean or equivalent in a safe and clean environment (clean aluminum pan) clean
the valve body and dry it with compressed air. Use appropriate eye protection.
Clean individual valve body components with GM Brake Clean or equivalent. Coat each valve with
clean ATF and reassemble in each bore. Check each valve for free movement during assembly of
each bore.
Position the valve body as shown in the illustrations shown above for positive identification and
location of individual parts.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 10474
Valve Body: Locations
Ball Check Valve Locations
Ball Check Valve Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Valve Body: Service and Repair 6T70/6T75 - Automatic Transmission
Control Valve Body Cover Replacement
Control Valve Body Cover Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Remove the oil cooler inlet and outlet hoses from the retainer on the control valve body cover. 3.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 4. Remove the left engine
splash shield. Refer to Engine Splash Shield Replacement . 5. Remove the front transmission
mount. Refer to Transmission Front Mount Replacement (See: Transmission Mount/Service and
Repair/6T70/6T75 - Automatic Transmission/Transmission Front Mount Replacement) .
6. Drain the transmission. Refer to Transmission Fluid Replacement (See: Service and
Repair/Removal and Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10477
7. Disconnect the control valve body transmission control module (TCM) electrical connector (1).
8. Remove the 2 control valve body cover studs M6 x 30. 9. Remove the 12 control valve body
cover bolts M6 x 30.
10. Support the transmission with a transmission jack. 11. Using the transmission jack raise the
transmission to gain clearance for removal of the control valve body cover. 12. Remove the control
valve body cover. 13. Remove the control valve body cover gasket.
Notice: Support the control solenoid valve assembly around the connector when removing the seal.
Excessive pulling force can damage the internal electrical connections.
14. Remove the control valve body cover wiring connector hole seal. 15. Remove all traces of the
old gasket material. Clean the transmission case and control valve body cover gasket surfaces.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10478
Important: The holes in the control valve body cover wiring connector hole seal must face toward
the control solenoid valve assembly. If the holes face toward the valve body cover, there is a
potential for a leak around the seal.
1. Install the control valve body cover wiring connector hole seal. 2. Install the control valve body
cover gasket to the control valve body cover. 3. Install the control valve body cover. 4. Lower the
transmission and remove the transmission jack.
Notice: Refer to Fastener Notice .
Important: Install all control valve body cover bolts and studs by hand then torque all bolts and
studs in sequence.
5. Install the 12 control valve body cover bolts (1) M6 x 30.
Tighten the bolts in sequence to 12 N.m (106 lb in).
6. Install the 2 control valve body cover studs (2) M6 x 30.
Tighten the studs in sequence to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10479
7. Connect the control valve body TCM electrical connector (1). 8. Install the lower nuts to the left
transmission mount. Refer to Transmission Mount Replacement - Left Side (See: Transmission
Mount/Service and
Repair/6T70/6T75 - Automatic Transmission/Transmission Mount Replacement - Left Side) .
9. Install the front transmission mount. Refer to Transmission Front Mount Replacement (See:
Transmission Mount/Service and Repair/6T70/6T75 Automatic Transmission/Transmission Front Mount Replacement) .
10. Install the left engine splash shield. Refer to Engine Splash Shield Replacement . 11. Lower the
vehicle.
12. Install the oil cooler inlet and outlet hoses to the retainer on the control valve body cover. 13.
Install the battery tray. Refer to Battery Tray Replacement . 14. Fill the transmission. Refer to
Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement) . 15.
Check for leaks.
Control Valve Lower Body and Upper Body Replacement
Control Valve Lower Body and Upper Body Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10480
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Control Valve Body Cover Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with removal of lower control valve body. 7. Remove the 2
control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove
the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10481
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve body assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the PCS switch feed holes could cause leakage around the PCS switch
seals. Replace the upper channel plate as necessary.
13. Remove the 8 control valve body bolts (2) M6 x 65. 14. Remove the 2 control valve body bolts
(1) M6 x 55. 15. Remove the manual shaft detent assembly (3). 16. Remove the control valve body
assembly (4). 17. The control solenoid valve spring can now be fully removed from the lower
control valve body assembly.
Important: The clutch fluid passage seal is not reusable.
18. Remove the 1-2-3-4 clutch fluid passage seal (5).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10482
Important: The clutch fluid passage seal is not reusable.
1. Install a NEW 1-2-3-4 clutch fluid passage seal (3).
Important: Ensure the control solenoid valve spring is attached to the lower control valve body
assembly.
Important: Align the manual valve (2) to the detent lever assembly while installing the lower control
valve body assembly.
2. Install the control valve body assembly (1).
Important: Ensure proper alignment of the detent assembly to the detent lever assembly with
position switch while tightening the bolt. The detent assembly can move and hit the valve body
assembly that could cause improper engagement with the detent lever assembly.
3. Install the manual shaft detent assembly (2).
Notice: Refer to Fastener Notice .
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
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Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 8 control valve body bolts (1) M6 x 65.
Tighten the bolts in specified sequence to 12 N.m (106 lb in).
5. Install the 2 control valve body bolts (3) M6 x 55.
Tighten the bolts in specified sequence to 12 N.m (106 lb in).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
6. Install a NEW control solenoid valve assembly filter plate (1).
7. Install the control solenoid valve body and TCM assembly (5).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10484
8. Rotate the control solenoid valve spring (7) into position.
Important: Install all bolts before tightening, then tighten in specified sequence.
9. Install the 4 control valve body bolts (1) M6 x 80.
10. Install the control valve body bolt (6) M6 x 55. 11. Install the 3 control valve body bolts (2) M6 x
95. 12. Install the control valve body bolt (3) M6 x 42. 13. Install the 2 control valve body bolts (4)
M6 x 65.
14. Connect the input speed sensor electrical connector (1). 15. Connect the output speed sensor
electrical connector (2). 16. Connect the shift position switch electrical connector (3). 17. Install the
control valve body cover. Refer to Control Valve Body Cover Replacement (See: Control Valve
Body Cover Replacement) . 18. For transmission control module programming and setup. Refer to
Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
19. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Testing and Inspection/Component Tests and General
Diagnostics/6T70/6T75 - Automatic Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10485
Valve Body: Service and Repair AF33-5 - Automatic Transaxle
Control Valve Body Cover Replacement
Control Valve Body Cover Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the left front wheel and
tire assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service
and Repair) .
3. Remove the left splash shield. Refer to Engine Splash Shield Replacement . 4. Remove the front
engine mount. Refer to Engine Front Mount Replacement . 5. Remove the transaxle oil cooler lines
and seals from the transaxle. Refer to Fluid Cooler Pipe Seal Replacement (See: Fluid
Line/Hose/Service
and Repair) .
6. Remove the 9 TORX bolts (2) from the control valve body cover (1).
Important: Do not pry with a tool on the transaxle control valve body cover, case or sealing
surfaces.
7. Remove control valve body cover.
Installation Procedure
1. Clean any gasket material from the control valve body cover and inspect the gasket mounting
surface. 2. Install a 3 mm (0.125 in) bead of RTV sealer GM P/N 89020326 (Canadian P/N
89021188) onto the control valve body cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10486
3. Install the control valve body cover (1) onto the transaxle case.
Important: Use LOCTITE(TM) 242 thread sealer on ALL bolt threads.
4. Install the control valve body cover bolts (2) hand tight.
Notice: Refer to Fastener Notice .
5. Tighten the control valve body cover bolts in the sequence shown.
Tighten the bolts to 13 N.m (115 lb in).
6. Install the transaxle oil cooler lines and seals to the transaxle. Refer to Fluid Cooler Pipe Seal
Replacement (See: Fluid Line/Hose/Service and
Repair) .
7. Install the front engine mount. Refer to Engine Front Mount Replacement . 8. Install the left
splash shield. Refer to Engine Splash Shield Replacement . 9. Install the left front wheel and the
tire assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and
Tires/Service
and Repair) .
10. Lower the vehicle. 11. Check the transaxle fluid level. Refer to Transmission Fluid Check (See:
Testing and Inspection/Component Tests and General
Diagnostics/AF33-5 - Automatic Transaxle/Transmission Fluid Check) .
Control Valve Body Replacement
Control Valve Body Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10487
Important: Place the transaxle in neutral (N).
1. Remove the transmission wiring harness. Refer to Automatic Transmission Wiring Harness
Replacement (See: Wiring Harness/Service and
Repair) .
2. Remove the 2 control valve body bolts/screws (31), control valve body fluid passage cover (37)
and gasket (38).
3. Remove the 6 control valve body mounting bolts/screws (1-6).
4. While holding the control valve body assembly, disconnect the manual shift detent lever
assembly (710) from the manual valve link (336). 5. Move the detent lever assembly clockwise for
ease of removing the manual valve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10488
6. Remove the control valve body assembly (39).
7. Remove the 2 transaxle case fluid passage seals (86).
Installation Procedure
1. Install 2 new transaxle case fluid passage seals (86) into the transaxle case fluid ports.
2. While holding the control valve body assembly (39), connect the manual valve link (336) to the
manual shift detent lever assembly (710).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10489
3. Install the 6 control valve body assembly to transaxle case bolts and hand tighten.
Notice: Refer to Fastener Notice .
4. Tighten the control valve body assembly-to-transaxle case bolts in sequence.
Tighten the bolts to 10 N.m (89 lb in).
5. Install a new control valve body fluid passage cover gasket (38). 6. Install the control valve body
fluid passage cover (37). 7. Install the 2 control valve body bolts (31).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 10490
Tighten the bolt to 10 N.m (89 lb in).
8. Install the transmission wiring harness. Refer to Automatic Transmission Wiring Harness
Replacement (See: Wiring Harness/Service and Repair)
.
9. After the transmission is reassembled and filled with fluid perform the transmission adaptive
learn procedure. Refer to Transmission Adaptive
Learn and Transmission Neutral Learn (See: Testing and Inspection/Component Tests and
General Diagnostics/AF33-5 - Automatic Transaxle/Transmission Adaptive Learn and
Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair
Wiring Harness: Service and Repair
Automatic Transmission Wiring Harness Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/AF33-5 Automatic Transaxle/Control Valve Body Cover Replacement) .
2. Disconnect the wiring harness connectors (1-8).
3. Remove the fluid temperature sensor bolt (31). 4. Remove the fluid temperature sensor clamp
(49). 5. Remove the fluid temperature sensor (36) and the O-ring (32) from the control valve body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 10494
6. Remove the A/T control wiring harness connector retainer (69).
7. Remove the transmission wiring harness assembly (33) from the transmission case assembly
through the wiring harness bore. 8. Remove the TCM seal (72) and the automatic transmission
wiring connector seal (46) from the connector.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 10495
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to a NEW transaxle wiring connector
O-ring seal (46). 2. Install the NEW automatic transmission wiring connector seal (46) in the bore
for the connector. The taper side of the seal goes up. 3. Install a NEW TCM seal (72) on the
connector. 4. Install the transmission wiring harness assembly (33) into the transmission case
assembly through the wiring harness bore.
5. Align the tab of the connector in the transmission case. 6. Install the wiring harness connector
retainer (69).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 10496
7. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to a new transaxle fluid temperature
sensor O-ring seal (32). 8. Install a new transaxle fluid temperature sensor O-ring seal (32) into the
groove of the transaxle fluid temperature sensor (36). 9. Install the transaxle fluid temperature
sensor (36) into the front control valve body fluid temperature sensor bore.
10. Install the transaxle fluid temperature sensor clip (49).
Notice: Refer to Fastener Notice .
11. Install the fluid temperature sensor bolt (31).
Tighten the bolt to 10 N.m (89 lb in).
12. Connect the 8 solenoid wire connectors as follows:
* 1 blue
* 2 black
* 3 green
* 4 black
* 5 blue
* 6 gray
* 7 brown
* 8 black
13. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Valve Body/Service and Repair/AF33-5 - Automatic
Transaxle/Control Valve Body Cover Replacement) .
14. Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Testing and
Inspection/Component Tests and General Diagnostics/AF33-5 - Automatic Transaxle/Transmission
Adaptive Learn and Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information
Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information
INFORMATION
Bulletin No.: 07-07-30-010B
Date: June 19, 2009
Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using
TIS Software
Models:
2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models)
2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section
and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section
07 - Transmission/Transaxle).
Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles
when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool
platform and software will be required for use with all GM Global Architecture (Global A) vehicles
beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet
Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R)
communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number
09-00-89-019 (Introduction of New Global Diagnostic System (GDS)).
This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and
upload it to a computer. The procedure is written for an automatic transmission data snapshot on a
Saturn AURA, but is similar for all applications. This procedure is written with the assumption the
user has a basic understanding of how to use a Tech 2(R) already.
Capturing a Snapshot of the Vehicle Data Stream
1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi
module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen.
3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the
scan tool's display. Bolded selections are vehicle specific.
- Select "2007"
- Select "Passenger Car (F0)"
- Select "Saturn"
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10501
- Select "Z"
- Select "Aura"
- Select "Powertrain"
- Select "3.6L LY7"
- Select "Transmission"
- Select "Transmission Data"
5. From the application menu, select F3: Snapshot.
- Choose trigger type and trigger point, as described above.
- It is preferred to trigger on "Any Code" (F1)
- If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on
the next screen.
- Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the
events before and after the code sets.
6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going
to record for live viewing.
- When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1
and F5) are selected.
- If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key
to actually record data. Otherwise, it will automatically start recording when a DTC is set.
- Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1
minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is
selected).
Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third
snapshot is requested, the first snapshot will be overwritten.
7. When the snap shot data has been recorded, exit to the Main Menu, then power down and
disconnect the Tech 2(R) from the vehicle.
Uploading and Sending a Snapshot via TIS2WEB
Figure 8
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10502
Figure 9
1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a
arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen
just like the TIS 2000 procedure described above.
Figure 10
3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure
10. Make sure the Tech 2(R) is connected to the
computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech
2(R) should start blinking and a line will start scrolling across the screen indicating it is
communicating with your computer.
Figure 11
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10503
4. Once communication is established and you select the file you want to upload, you will see a
screen similar to below. You can email the file
directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail"
as shown in Figure 11.
Figure 12
5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill
in the information as requested and then click
send. Include the VIN in the subject line.
6. After all the information is entered, hit the send button. After sending the file, you will receive a
confirmation box letting you know the e-mail was
sent successfully.
7. It is recommended to now save the file to your computer using the same procedure as if you
were using TIS 2000 in case your recipient doesn't
receive your email with the snapshot data.
Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is
no way to access your sent mail in TIS2WEB like a regular e-mail program.
Sending a Snapshot to GM TAC
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10504
During your call with GM TAC on a current case, you may be advised to send a copy of the Tech
2(R) or VDR Snapshot Data to the TAC e-mail box.
U.S. Dealers - send to e-mail box
[email protected]
Canadian Dealers - send to e-mail box
[email protected]
Please complete the following:
- Be sure to review the procedures listed above for uploading and sending a Snapshot via
TIS2WEB.
- If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink
Website in the articles (December 2002, December 2003, July 2004 and January 2006).
- Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of
the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The
email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email
can not be processed and will be deleted.
Please send only REQUESTED Snapshot Data to the TAC e-mail box.
Disclaimer
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10505
Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine
Crankcase and Subsystems Flushing Info.
INFORMATION
Bulletin No.: 04-06-01-029E
Date: April 29, 2010
Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM
Simplified Maintenance Schedule to Enhance Customer Service Experience
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and add information about the
proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D
(Section 06 - Engine/Propulsion System).
An Overview of Proper Vehicle Service
General Motors is aware that some companies are marketing tools and equipment to support a
subsystem flushing procedures. These dedicated machines are in addition to many engine oil,
cooling system, fuel system, A/C, transmission flush and steering system additives available to the
consumer. GM Vehicles under normal usage do not require any additional procedures or additives
beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified
Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are
designed to aid and accelerate the process of fluid changing with these flushing machines.
Engine Crankcase Flushing
General Motors Corporation does not endorse or recommend engine crankcase flushing for any of
its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing
indicate incompatibility with GM engine components and the potential for damage to some engine
seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT
COVERED under the terms of the New Vehicle Warranty.
GM Authorized Service Information: Detailed, Descriptive, and Complete
If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service
Document containing a procedure and, if required, provide, make available, or require the specific
use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is
fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has
recognized the need for fuel injector cleaning methods on some engines, though under normal
circumstances, this service is not part of the maintenance requirements.
GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to
be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning
of the fuel injectors with preventative maintenance suggestions to maintain optimum performance.
You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional
information on this subject.
Subsystem Flushing
Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized
practices to be performed after catastrophic failures or extreme corrosion when encountered in
radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006.
This practice is NOT required or recommended for normal service operations.
The use of external transmission fluid exchange or flush machines is NOT recommended for the
automatic or manual transmission. Use of external machines to replace the fluid may affect the
operation or durability of the transmission. Transmission fluid should only be replaced by draining
and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter
Replacement.
Approved Transmission Flushing Tool (Transmission Cooler Only)
The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM
vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096.
Service Is Important to You and Your Customer
General Motors takes great pride in offering our dealerships and customers high quality vehicles
that require extremely low maintenance over the life of the vehicle. This low cost of ownership
builds repeat sales and offers our customers measurable economy of operation against competing
vehicles.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 10506
Providing responsible services at the proper intervals will greatly aid your dealership with repeat
business, and additional services when required. Most customers appreciate and gain trust in the
dealership that informs and offers them just what they need for continued trouble-free operation.
Examine your service department's practices and verify that all Service Consultants and
Technicians focus on customer satisfaction, vehicle inspections, and other products at time of
service. Use this opportunity to upgrade the services you provide to your customers. Here are a
few suggestions:
- Take the time required to align your dealership service practices with the new GM Simplified
Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to
create a "mirror image" in your advertising and dealer service pricing that is easily understandable
to your customer. Taking advantage of this new service strategy may greatly increase your
dealership service sales and customer retention while decreasing the frequency of visits and
inconvenience to your customer.
- Review your program to ensure that all vehicles coming in are evaluated for safety and wear
items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp
functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service
Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is
illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and
what the required repair would cost. In addition to the possibility of increased emissions and
driveability concerns, many customers are unaware that lower gas mileage may also result, with
additional cost to the customer.
- Be complete in your service recommendations. Some sales opportunities are not being fully
pursued nationally. Focus on overlooked but required maintenance that has real benefits to the
customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond
replacement time, they may impede airflow decreasing A/C and heating performance. Make sure
these filters are part of your recommended service. Note that some of our vehicles may not have
been factory equipped but will accept the filters as an accessory.
- Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I
and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's
world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic
car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax
to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase
customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source
of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved
resale value of a completely maintained vehicle.
- For customers who clean and maintain the appearance of their vehicles themselves encourage
the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax
Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of
many customers who try it just once. If your dealership give samples of these products with new
car purchases, customers may already be sold on the product but not willing to make a special trip
to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with
these products and consider instituting compensation programs for Service Consultants who
suggest these products. Many consumers faced with an intimidating wall full of car care products
sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM
that they know will not harm the finish of their vehicle. We suggest these competitively priced basic
vehicle care products to emphasize:
In USA:
- #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L)
- #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g)
- #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L)
- #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L)
- #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L)
In Canada:
- #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL
- #992727 GM Glass Cleaner Aerosol 500 g
- #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL
- #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL
- #10953202 GM Vehicle Care Wheel Brite 473 mL
- #88901678 GM Vehicle Care Odor Eliminator 473 mL
- Display signboards with the installed price for popular GM Accessories such as running boards
and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a
service visit.
- Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit
Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer
with more reasons to identify your dealership as the best place to go for parts and service.
Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and
provide value to your customer. Many businesses exist profitably as an oil change location, a
vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and
provide these services with the inherent trust of your customer, under the GM Mark of Excellence.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Service and Repair
Differential Cover: Service and Repair
Differential Carrier Cover and Seal Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Control Unit,
Differential Lock > Component Information > Service and Repair > Rear Differential Clutch Control Module Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Control Unit,
Differential Lock > Component Information > Service and Repair > Rear Differential Clutch Control Module Replacement >
Page 10516
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front)
Differential Mount: Service and Repair Differential Housing Support Bushing Replacement (Front)
Differential Housing Support Bushing Replacement (Front)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10521
Differential Mount: Service and Repair Differential Housing Support Bushing Replacement (Rear)
Differential Housing Support Bushing Replacement (Rear)
Tools Required
J-45725 Cradle Bushing Replacer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear
differential assembly. Refer to Differential Replacement (See: Service and Repair/Removal and
Replacement/Differential
Replacement) .
3. Mark a reference point on the frame and old bushing at the 12 and 6 o'clock position to use to
alignment the new bushing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10522
4. Position the J-45725-1A (1) on the bushing (2). 5. Position the J-45725-2A (1) on the frame.
Important: Apply a small amount of grease on the threaded rod to lubricate the nuts when turning
the nuts.
6. Install the threaded rod, bearing and washers.
7. Adjust the nuts so that they are touching the J-45725-1A (2) and the J-45725-2A (1). 8. Install
the proper size wrenches on the nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10523
Important: In the following service procedure, use only HAND TOOLS when using the J-45725.
9. While holding the front wrench (1) rotate the rear wrench (2) to remove the bushing.
10. Remove the special tools.
11. Remove the bushing from the frame.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10524
Important: Failure to perform the following service procedure prior to the installation of the new
bushing, could cause premature failure of the bushing.
1. Before the installation of the new bushing, use a straight edge draw a line on the new bushing at
the 12 and 6 o'clock positions. Ensure that the
grooves (1) are at the 12 and 6 o'clock positions.
2. Position the new bushing so that the reference marks on the frame and the bushing are in
alignment. This will ensure that the new bushing will be
within the + or - 5° specification required for the proper alignment of the bushing.
Important: The following procedure is to temporarily hold the new bushing in place so that the
special tools can be installed for the proper installation. This is NOT to be used to install the
bushing.
3. Using a block of wood and a hammer, slightly tap the bushing into the frame. 4. Assemble the
threaded rod, bearings and washers as indicated in step 7 in the removal procedure.
5. Position the J-45725-4 (2) on the inside of the frame. 6. Position J-45725-1A (1) on the outside
of the frame. 7. Adjust the nuts so that they are touching the J-45725-2 (1) and the J-45725-2A (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10525
8. While holding the front wrench (2) rotate the rear wrench (1) to install the bushing. 9. Remove
the special tools.
10. Install the rear differential assembly. Refer to Differential Replacement (See: Service and
Repair/Removal and Replacement/Differential
Replacement) .
11. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component
Information > Service and Repair > Differential Housing Support Bushing Replacement (Front) > Page 10526
Differential Mount: Service and Repair Differential Carrier Assembly Mount Replacement
Differential Carrier Assembly Mount Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Rear Differential ...................................................................................................................................
................................................ 500 ml (16.9 ounces)
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 10531
Fluid - Differential: Fluid Type Specifications
CARRIER ASSEMBLY -- DIFFERENTIAL (REAR DRIVE MODULE) Axle Lubricant (GM Part No.
U.S. 89021677, in Canada 89021678).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures
Fluid - Differential: Procedures
Rear Axle Lubricant Level Inspection
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Service and Repair > Procedures > Page 10534
Fluid - Differential: Removal and Replacement
Rear Axle Lubricant Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential >
Component Information > Service and Repair
Pinion Flange: Service and Repair
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Relays and Modules - Differential >
Control Unit, Differential Lock > Component Information > Service and Repair > Rear Differential Clutch Control Module
Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Relays and Modules - Differential >
Control Unit, Differential Lock > Component Information > Service and Repair > Rear Differential Clutch Control Module
Replacement > Page 10543
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Differential Carrier Cover and Seal Replacement - Left Side
Seals and Gaskets: Service and Repair Differential Carrier Cover and Seal Replacement - Left
Side
Differential Carrier Cover and Seal Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential >
System Information > Service and Repair > Differential Carrier Cover and Seal Replacement - Left Side > Page 10548
Seals and Gaskets: Service and Repair Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Inner Joint and Boot
Replacement
Front Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Position wheel drive shaft bar in a soft jawed vise and clamp securely. 2. Using side cutters,
remove and discard the small seal clamp.
3. Remove large seal retaining clamp using a flat-bladed tool and discard the clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10555
4. Separate the seal from the tripot housing at the large diameter and slide the seal away from the
joint along the axle shaft. 5. Wipe the excess grease from the face of the tripot spider and the
inside of the tripot housing. 6. Remove the tripot housing from the spider and shaft.
7. Remove the retaining ring from the groove on the wheel drive shaft bar and remove the spider
assembly. 8. Remove the seal from the wheel drive shaft bar. 9. Thoroughly clean all parts with a
suitable solvent, removing all traces of grease and contaminants.
10. Dry all parts with compressed air. 11. Inspect the tripot joint components for unusual wear,
cracks, and other damage. Replace any damaged components.
Assembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10556
1. Install the small seal clamp to the seal. Do not crimp the clamp. 2. Slide the inner seal onto the
wheel drive shaft bar and locate the lip of the seal groove on the wheel drive shaft bar.
Important: Ensure the seal clamp is positioned correctly in the seal groove.
3. Using the J 35910 , crimp the small seal clamp. 4. Measure the clamp gap width.
Clamp gap width should not exceed 2.15 mm (0.085 in).
5. Install the tripot spider assembly to the wheel drive shaft bar, until seated against shoulder. 6.
Install the retaining ring in the groove of the wheel drive shaft bar with suitable pliers. 7. Place
approximately half of the grease in the kit to the seal and place the remainder in the tripot housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10557
8. Install the large clamp over the large diameter of the seal. 9. Install the tripot housing to the tripot
spider assembly on the wheel drive shaft bar.
10. Slide the large diameter of the seal over the outside of the tripot housing and position the lip of
the seal in the housing groove.
11. Place the large seal retaining clamp around the seal and close using J 35910 . 12. Inspect the
gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
13. Rotate the housing in a circular motion to distribute the grease in the tripot joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10558
Constant Velocity Joint: Service and Repair Rear Wheel Drive Shaft Inner Joint and Boot
Replacement
Rear Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Position wheel drive shaft bar in a soft jawed vise and clamp securely. 2. Using side cutters,
remove and discard the small seal clamp.
3. Remove large seal retaining clamp using a flat-bladed tool and discard the clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10559
4. Separate the seal from the tripot housing at the large diameter and slide the seal away from the
joint along the axle shaft. 5. Wipe the excess grease from the face of the tripot spider and the
inside of the tripot housing. 6. Remove the tripot housing from the spider and shaft.
7. Remove the retaining ring from the groove on the wheel drive shaft bar and remove the spider
assembly. 8. Remove the seal from the wheel drive shaft bar. 9. Thoroughly clean all parts with a
suitable solvent, removing all traces of grease and contaminants.
10. Dry all parts with compressed air. 11. Inspect the tripot joint components for unusual wear,
cracks, and other damage. Replace any damaged components.
Assembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10560
1. Install the small seal clamp to the seal. Do not crimp the clamp. 2. Slide the inner seal onto the
wheel drive shaft bar and locate the lip of the seal groove on the wheel drive shaft bar.
Important: Ensure the seal clamp is positioned correctly in the seal groove.
3. Using the J 35910 , crimp the small seal clamp. 4. Measure the clamp gap width.
Clamp gap width should not exceed 2.15 mm (0.085 in).
5. Install the tripot spider assembly to the wheel drive shaft bar, until seated against shoulder. 6.
Install the retaining ring in the groove of the wheel drive shaft bar . 7. Place approximately half of
the grease in the kit to the seal and place the remainder in the tripot housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10561
8. Install the large clamp over the large diameter of the seal. 9. Install the tripot housing to the tripot
spider assembly on the wheel drive shaft bar.
10. Slide the large diameter of the seal over the outside of the tripot housing and position the lip of
the seal in the housing groove.
11. Place the large seal retaining clamp around the seal and close using J 35910 . 12. Inspect the
gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
13. Rotate the housing in a circular motion to distribute the grease in the tripot joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10562
Constant Velocity Joint: Service and Repair Front Wheel Drive Shaft Outer Joint and Boot
Replacement
Front Wheel Drive Shaft Outer Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Clamp the drive axle shaft in a soft jawed vice.
2. Use a flat-bladed tool and disengage the retaining tabs of the large seal clamp. 3. Discard the
clamp. 4. Remove the small seal clamp using side cutters and discard the clamp. 5. Separate the
constant velocity (CV) joint boot from the CV joint race at the large diameter. 6. Slide the boot away
from the joint along the wheel drive shaft bar.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10563
7. Wipe the excess grease from the face of the CV inner race.
8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove
it from the wheel drive shaft bar. 9. Remove the seal from the wheel drive shaft bar.
10. Remove the CV joint retaining ring from the wheel drive shaft bar.
11. Place a brass drift against the CV joint inner race (1). 12. Tap gently on the brass drift with a
hammer in order to tilt the joint race.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10564
13. Remove the first bearing roller (2) when the CV race tilts. 14. Repeating the steps above, tilt the
CV joint inner race in the opposite direction to remove the opposing bearing roller. 15. Repeat the
process to remove all 6 of the bearing rollers.
16. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (2).
At the same time, align the cage windows (3) with
the lands of the outer race.
17. Lift out the cage (4) and the inner race.
18. Remove the inner race (1) from the cage (2) by rotating the inner race upward. 19. Clean the
following items thoroughly with a suitable solvent. Remove all traces of grease and contaminants.
* The inner and outer race assemblies.
* The CV joint cage.
* The bearing rollers.
20. Dry all the parts with compressed air. 21. Inspect the CV joint assembly for the following:
* Unusual wear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10565
* Cracks
* Damage
22. Replace any damaged parts. 23. Clean the wheel drive shaft bar. Use a wire brush to remove
any rust in the seal mounting grooves.
Installation Procedure
1. Install the new small seal clamp (2) on the neck of the outboard seal (1). Do not clamp. 2. Slide
the outboard seal onto the wheel drive shaft bar and position the neck of the outboard seal in the
seal groove on the bar. The largest groove
below the sight groove on the wheel drive shaft bar is the seal groove seal (3).
Important: Ensure that the seal clamp is properly positioned around the entire circumference of the
seal.
3. Crimp the seal clamp using the J 35910 . 4. Measure the clamp end gap dimension. The gap
should not exceed 2.15 mm (0.085 in).
The gap should not exceed 2.15 mm (0.085 in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10566
5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race and
outer race. 6. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race
(1) aligned with the windows of the cage (2) and insert the
inner race into the cage.
7. Hold the cage and inner race 90 degrees to the center line of the outer race (1) and align the
cage windows (3) with the lands of the outer race.
Important: Be sure that the retaining ring side of the inner race faces the wheel drive shaft bar.
8. Place the cage and the inner race into the outer race. 9. Insert the first bearing roller, then tilt the
cage to insert every other bearing roller.
10. Repeat this process until all 6 bearing rollers are in place. 11. Install the CV joint retaining ring
to the wheel drive shaft bar. 12. Place approximately half the grease from the service kit inside the
outboard seal and pack the CV joint with the remaining grease.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10567
13. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV
joint inner race engages the retaining ring. 14. Slide the large diameter of the seal over the outside
of the CV race and locate the lip of the seal in the housing groove. 15. Install the large seal
retaining clamp over the seal and close using the J 35910 16. Inspect the gap dimension on the
clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
17. Remove the wheel drive shaft from the bench vise. 18. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion four to five times.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10568
Constant Velocity Joint: Service and Repair Rear Wheel Drive Shaft Outer Joint and Boot
Replacement
Rear Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
J 35910 Drive Axle Boot Clamp Pliers
Disassembly Procedure
1. Clamp the drive axle shaft in a soft jawed vice.
2. Use a flat-bladed tool and disengage the retaining tabs of the large boot clamp. 3. Discard the
clamp. 4. Remove the small boot clamp using side cutters and discard the clamp. 5. Separate the
constant velocity (CV) joint boot from the CV joint race at the large diameter. 6. Slide the boot away
from the joint along the wheel drive shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10569
7. Wipe the excess grease from the face of the CV inner race.
8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove
it from the wheel drive shaft. 9. Remove the boot from the wheel drive shaft.
10. Remove the CV joint retaining ring from the wheel drive shaft. 11. Clean the wheel drive shaft.
Use a wire brush to remove any rust in the boot mounting grooves.
Installation Procedure
1. Install the new small boot clamp (2) on the neck of the outboard boot (1). Do not clamp. 2. Slide
the outboard boot onto the wheel drive shaft and position the neck of the outboard boot in the boot
groove on the shaft. The largest groove
below the sight groove on the wheel drive shaft is the boot groove boot (3).
Important: Ensure that the boot clamp is properly positioned around the entire circumference of the
boot.
3. Crimp the boot clamp using the J 35910 . 4. Measure the clamp end gap dimension. The gap
should not exceed 2.15 mm (0.85 in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10570
The gap should not exceed 2.15 mm (0.85 in).
5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race (1)
and outer race (2). 6. Using pliers, install the CV joint retaining ring to the wheel drive shaft. 7.
Place approximately half the grease from the service kit inside the outboard boot and pack the CV
joint with the remaining grease.
8. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV joint
inner race engages the retaining ring. 9. Slide the large diameter of the boot over the outside of the
CV race and locate the lip of the boot in the housing groove.
10. Install the large boot retaining clamp over the boot and close using the J 35910 . 11. Inspect
the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
12. Remove the wheel drive shaft from the bench vise. 13. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion 4 to 5 times.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement
Constant Velocity Joint Boot: Service and Repair Front Wheel Drive Shaft Inner Joint and Boot
Replacement
Front Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Position wheel drive shaft bar in a soft jawed vise and clamp securely. 2. Using side cutters,
remove and discard the small seal clamp.
3. Remove large seal retaining clamp using a flat-bladed tool and discard the clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10575
4. Separate the seal from the tripot housing at the large diameter and slide the seal away from the
joint along the axle shaft. 5. Wipe the excess grease from the face of the tripot spider and the
inside of the tripot housing. 6. Remove the tripot housing from the spider and shaft.
7. Remove the retaining ring from the groove on the wheel drive shaft bar and remove the spider
assembly. 8. Remove the seal from the wheel drive shaft bar. 9. Thoroughly clean all parts with a
suitable solvent, removing all traces of grease and contaminants.
10. Dry all parts with compressed air. 11. Inspect the tripot joint components for unusual wear,
cracks, and other damage. Replace any damaged components.
Assembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10576
1. Install the small seal clamp to the seal. Do not crimp the clamp. 2. Slide the inner seal onto the
wheel drive shaft bar and locate the lip of the seal groove on the wheel drive shaft bar.
Important: Ensure the seal clamp is positioned correctly in the seal groove.
3. Using the J 35910 , crimp the small seal clamp. 4. Measure the clamp gap width.
Clamp gap width should not exceed 2.15 mm (0.085 in).
5. Install the tripot spider assembly to the wheel drive shaft bar, until seated against shoulder. 6.
Install the retaining ring in the groove of the wheel drive shaft bar with suitable pliers. 7. Place
approximately half of the grease in the kit to the seal and place the remainder in the tripot housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10577
8. Install the large clamp over the large diameter of the seal. 9. Install the tripot housing to the tripot
spider assembly on the wheel drive shaft bar.
10. Slide the large diameter of the seal over the outside of the tripot housing and position the lip of
the seal in the housing groove.
11. Place the large seal retaining clamp around the seal and close using J 35910 . 12. Inspect the
gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
13. Rotate the housing in a circular motion to distribute the grease in the tripot joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10578
Constant Velocity Joint Boot: Service and Repair Rear Wheel Drive Shaft Inner Joint and Boot
Replacement
Rear Wheel Drive Shaft Inner Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Position wheel drive shaft bar in a soft jawed vise and clamp securely. 2. Using side cutters,
remove and discard the small seal clamp.
3. Remove large seal retaining clamp using a flat-bladed tool and discard the clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10579
4. Separate the seal from the tripot housing at the large diameter and slide the seal away from the
joint along the axle shaft. 5. Wipe the excess grease from the face of the tripot spider and the
inside of the tripot housing. 6. Remove the tripot housing from the spider and shaft.
7. Remove the retaining ring from the groove on the wheel drive shaft bar and remove the spider
assembly. 8. Remove the seal from the wheel drive shaft bar. 9. Thoroughly clean all parts with a
suitable solvent, removing all traces of grease and contaminants.
10. Dry all parts with compressed air. 11. Inspect the tripot joint components for unusual wear,
cracks, and other damage. Replace any damaged components.
Assembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10580
1. Install the small seal clamp to the seal. Do not crimp the clamp. 2. Slide the inner seal onto the
wheel drive shaft bar and locate the lip of the seal groove on the wheel drive shaft bar.
Important: Ensure the seal clamp is positioned correctly in the seal groove.
3. Using the J 35910 , crimp the small seal clamp. 4. Measure the clamp gap width.
Clamp gap width should not exceed 2.15 mm (0.085 in).
5. Install the tripot spider assembly to the wheel drive shaft bar, until seated against shoulder. 6.
Install the retaining ring in the groove of the wheel drive shaft bar . 7. Place approximately half of
the grease in the kit to the seal and place the remainder in the tripot housing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10581
8. Install the large clamp over the large diameter of the seal. 9. Install the tripot housing to the tripot
spider assembly on the wheel drive shaft bar.
10. Slide the large diameter of the seal over the outside of the tripot housing and position the lip of
the seal in the housing groove.
11. Place the large seal retaining clamp around the seal and close using J 35910 . 12. Inspect the
gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
13. Rotate the housing in a circular motion to distribute the grease in the tripot joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10582
Constant Velocity Joint Boot: Service and Repair Front Wheel Drive Shaft Outer Joint and Boot
Replacement
Front Wheel Drive Shaft Outer Joint and Boot Replacement
Tools Required
J 35910 Drive Axle Seal Clamp Pliers
Disassembly Procedure
1. Clamp the drive axle shaft in a soft jawed vice.
2. Use a flat-bladed tool and disengage the retaining tabs of the large seal clamp. 3. Discard the
clamp. 4. Remove the small seal clamp using side cutters and discard the clamp. 5. Separate the
constant velocity (CV) joint boot from the CV joint race at the large diameter. 6. Slide the boot away
from the joint along the wheel drive shaft bar.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10583
7. Wipe the excess grease from the face of the CV inner race.
8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove
it from the wheel drive shaft bar. 9. Remove the seal from the wheel drive shaft bar.
10. Remove the CV joint retaining ring from the wheel drive shaft bar.
11. Place a brass drift against the CV joint inner race (1). 12. Tap gently on the brass drift with a
hammer in order to tilt the joint race.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10584
13. Remove the first bearing roller (2) when the CV race tilts. 14. Repeating the steps above, tilt the
CV joint inner race in the opposite direction to remove the opposing bearing roller. 15. Repeat the
process to remove all 6 of the bearing rollers.
16. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (2).
At the same time, align the cage windows (3) with
the lands of the outer race.
17. Lift out the cage (4) and the inner race.
18. Remove the inner race (1) from the cage (2) by rotating the inner race upward. 19. Clean the
following items thoroughly with a suitable solvent. Remove all traces of grease and contaminants.
* The inner and outer race assemblies.
* The CV joint cage.
* The bearing rollers.
20. Dry all the parts with compressed air. 21. Inspect the CV joint assembly for the following:
* Unusual wear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10585
* Cracks
* Damage
22. Replace any damaged parts. 23. Clean the wheel drive shaft bar. Use a wire brush to remove
any rust in the seal mounting grooves.
Installation Procedure
1. Install the new small seal clamp (2) on the neck of the outboard seal (1). Do not clamp. 2. Slide
the outboard seal onto the wheel drive shaft bar and position the neck of the outboard seal in the
seal groove on the bar. The largest groove
below the sight groove on the wheel drive shaft bar is the seal groove seal (3).
Important: Ensure that the seal clamp is properly positioned around the entire circumference of the
seal.
3. Crimp the seal clamp using the J 35910 . 4. Measure the clamp end gap dimension. The gap
should not exceed 2.15 mm (0.085 in).
The gap should not exceed 2.15 mm (0.085 in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10586
5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race and
outer race. 6. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race
(1) aligned with the windows of the cage (2) and insert the
inner race into the cage.
7. Hold the cage and inner race 90 degrees to the center line of the outer race (1) and align the
cage windows (3) with the lands of the outer race.
Important: Be sure that the retaining ring side of the inner race faces the wheel drive shaft bar.
8. Place the cage and the inner race into the outer race. 9. Insert the first bearing roller, then tilt the
cage to insert every other bearing roller.
10. Repeat this process until all 6 bearing rollers are in place. 11. Install the CV joint retaining ring
to the wheel drive shaft bar. 12. Place approximately half the grease from the service kit inside the
outboard seal and pack the CV joint with the remaining grease.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10587
13. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV
joint inner race engages the retaining ring. 14. Slide the large diameter of the seal over the outside
of the CV race and locate the lip of the seal in the housing groove. 15. Install the large seal
retaining clamp over the seal and close using the J 35910 16. Inspect the gap dimension on the
clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
17. Remove the wheel drive shaft from the bench vise. 18. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion four to five times.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10588
Constant Velocity Joint Boot: Service and Repair Rear Wheel Drive Shaft Outer Joint and Boot
Replacement
Rear Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
J 35910 Drive Axle Boot Clamp Pliers
Disassembly Procedure
1. Clamp the drive axle shaft in a soft jawed vice.
2. Use a flat-bladed tool and disengage the retaining tabs of the large boot clamp. 3. Discard the
clamp. 4. Remove the small boot clamp using side cutters and discard the clamp. 5. Separate the
constant velocity (CV) joint boot from the CV joint race at the large diameter. 6. Slide the boot away
from the joint along the wheel drive shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10589
7. Wipe the excess grease from the face of the CV inner race.
8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove
it from the wheel drive shaft. 9. Remove the boot from the wheel drive shaft.
10. Remove the CV joint retaining ring from the wheel drive shaft. 11. Clean the wheel drive shaft.
Use a wire brush to remove any rust in the boot mounting grooves.
Installation Procedure
1. Install the new small boot clamp (2) on the neck of the outboard boot (1). Do not clamp. 2. Slide
the outboard boot onto the wheel drive shaft and position the neck of the outboard boot in the boot
groove on the shaft. The largest groove
below the sight groove on the wheel drive shaft is the boot groove boot (3).
Important: Ensure that the boot clamp is properly positioned around the entire circumference of the
boot.
3. Crimp the boot clamp using the J 35910 . 4. Measure the clamp end gap dimension. The gap
should not exceed 2.15 mm (0.85 in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Front Wheel Drive Shaft Inner Joint and Boot
Replacement > Page 10590
The gap should not exceed 2.15 mm (0.85 in).
5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race (1)
and outer race (2). 6. Using pliers, install the CV joint retaining ring to the wheel drive shaft. 7.
Place approximately half the grease from the service kit inside the outboard boot and pack the CV
joint with the remaining grease.
8. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV joint
inner race engages the retaining ring. 9. Slide the large diameter of the boot over the outside of the
CV race and locate the lip of the boot in the housing groove.
10. Install the large boot retaining clamp over the boot and close using the J 35910 . 11. Inspect
the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Dimension equals 1.9 mm (5/64 in).
12. Remove the wheel drive shaft from the bench vise. 13. Distribute the grease within the outer
CV joint by rotating the joint in a circular motion 4 to 5 times.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-04-21-002A >
Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area
Seals and Gaskets: Customer Interest Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-04-21-002A >
Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area > Page 10599
transmission fluid leak due to interference with the input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B >
May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
08-04-21-002A > Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Fluid Leak From Transfer
Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
08-04-21-002A > Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area > Page 10609
transmission fluid leak due to interference with the input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: >
08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10614
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-04-21-002A Date: 090622
Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10615
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a transmission fluid leak due to interference with the
input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 08-07-30-009B Date: 080501
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10616
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 08-04-21-002A Date: 090622
Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10617
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a transmission fluid leak due to interference with the
input shaft.
Seal Installation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10618
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 08-07-30-009B Date: 080501
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10619
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Technical Service Bulletin # 08-07-30-009B Date: 080501
A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks
TECHNICAL
Bulletin No.: 08-07-30-009B
Date: May 01, 2008
Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak,
Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part)
Models: 2001-2008 GM Passenger Cars
with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1)
Supercede:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
10620
This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin
Number 08-07-30-009A (Section 07 - Transmission/Transaxle).
Condition
Some customers may comment on a transmission oil leak and/or that the transmission slips in
gear.
Cause
An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid
build-up at axe sea.
Correction
Important:
DO NOT replace the transmission for above concerns.
Replace the third clutch housing with service P/N 8682114, which has revised bushing material to
extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E
Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side
Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Left Side
Rear Axle Shaft Seal Replacement - Left Side
Special Tools
* J 8092 Driver Handle
* J 33832 Rear Bearing Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Drain the rear
differential. Refer to Rear Axle Lubricant Replacement (See: Differential Assembly/Fluid Differential/Service and
Repair/Removal and Replacement) .
3. Remove the exhaust system. Refer to Exhaust System Replacement (LNJ) Exhaust System
Replacement (LY7) . 4. Remove the spare tire.
Important: In the following service procedure, it is not necessary to completely remove the propeller
shaft. Relocate the propeller shaft to the side and secure with mechanics wire or equivalent.
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement (See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair) .
6. Remove the left rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement (See: Axle
Shaft Assembly/Service and Repair/Rear Wheel
Drive Shaft Replacement) .
7. Support rear differential with a transmission jack stand.
8. Remove the left rear differential support bushing bolt. Refer to Differential Housing Support
Bushing Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10623
9. Remove the left differential mount (1).
10. Remove the right differential support bushing nut (2). Refer to Differential Housing Support
Bushing Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
11. Lower the differential to gain access to the axle shaft seal.
12. Using the appropriate tool, remove the axle shaft seal (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10624
1. Install the J 8092 to the J 33832 . 2. Using the J 8092 and the J 33832 , install the axle shaft seal
(1). 3. Lift and position the differential in the rear cradle.
4. Install the left rear support bolt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10625
5. Install right differential support bushing nut (2). Refer to Differential Housing Support Bushing
Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
6. Install the left differential mount (1). Refer to Differential Housing Support Bushing Replacement
(Rear) (See: Differential Assembly/Differential
Mount/Service and Repair/Differential Housing Support Bushing Replacement (Rear))Differential
Housing Support Bushing Replacement (Front) (See: Differential Assembly/Differential
Mount/Service and Repair/Differential Housing Support Bushing Replacement (Front)) .
7. Remove the transmission jack stand. 8. Install the left rear wheel drive shaft. Refer to Rear
Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair/Rear Wheel
Drive Shaft Replacement)
9. Install the propeller shaft. Refer to Propeller Shaft Replacement (See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair) .
10. Install the exhaust system. Refer to Exhaust System Replacement (LNJ) Exhaust System
Replacement (LY7) . 11. Remove the spare tire. 12. Fill the rear differential with fluid. Refer to Rear
Axle Lubricant Replacement (See: Differential Assembly/Fluid - Differential/Service and
Repair/Removal and Replacement)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10626
Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Right Side
Rear Axle Shaft Seal Replacement - Right Side
Special Tools
* J 8092 Driver Handle
* J 33832 Rear Bearing Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Drain the rear
differential. Refer to Rear Axle Lubricant Replacement (See: Differential Assembly/Fluid Differential/Service and
Repair/Removal and Replacement) .
3. Remove the exhaust system. Refer to Exhaust System Replacement (LNJ) Exhaust System
Replacement (LY7) . 4. Remove the spare tire.
Important: In the following service procedure, it is not necessary to completely remove the propeller
shaft. Relocate the propeller shaft to the side and secure with mechanics wire or equivalent.
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement (See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair) .
6. Remove the right rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement (See:
Axle Shaft Assembly/Service and Repair/Rear
Wheel Drive Shaft Replacement) .
7. Support rear differential with a transmission jack stand.
8. Remove the right rear differential support bushing bolt. Refer to Differential Housing Support
Bushing Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10627
9. Remove the left differential mount (1).
10. Remove the right differential support bushing nut (2). Refer to Differential Housing Support
Bushing Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
11. Lower the differential to gain access to the axle shaft seal.
12. Using the appropriate tool, remove the axle shaft seal (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10628
1. Install the J 8092 to the J 33832 . 2. Using the J 8092 and the J 33832 , install the axle shaft seal
(1). 3. Lift and position the differential in the rear cradle.
4. Install the left rear support bolt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Left Side > Page 10629
5. Install right differential support bushing nut (2). Refer to Differential Housing Support Bushing
Replacement (Rear) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Rear))Differential Housing Support Bushing Replacement (Front) (See: Differential
Assembly/Differential Mount/Service and Repair/Differential Housing Support Bushing
Replacement (Front)) .
6. Install the left differential mount (1). Refer to Differential Housing Support Bushing Replacement
(Rear) (See: Differential Assembly/Differential
Mount/Service and Repair/Differential Housing Support Bushing Replacement (Rear))Differential
Housing Support Bushing Replacement (Front) (See: Differential Assembly/Differential
Mount/Service and Repair/Differential Housing Support Bushing Replacement (Front)) .
7. Remove the transmission jack stand. 8. Install the right rear wheel drive shaft. Refer to Rear
Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair/Rear Wheel
Drive Shaft Replacement)
9. Install the propeller shaft. Refer to Propeller Shaft Replacement (See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair) .
10. Install the exhaust system. Refer to Exhaust System Replacement (LNJ) Exhaust System
Replacement (LY7) 11. Remove the spare tire. 12. Fill the rear differential with fluid. Refer to Rear
Axle Lubricant Replacement (See: Differential Assembly/Fluid - Differential/Service and
Repair/Removal and Replacement)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Removal Procedure
1. Remove the front brake rotor. Refer to Front Brake Rotor Replacement .
2. Disconnect the wheel speed sensor electrical connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 10635
3. Remove the wheel speed sensor electrical connector from the connector bracket.
4. Remove the front wheel drive shaft spindle nut. 5. Remove the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
6. Support the wheel drive shaft with heavy mechanic's wire or equivalent. 7. Remove and discard
the wheel bearing/hub mounting bolts. 8. Remove the wheel bearing/hub assembly from the
steering knuckle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 10636
1. Install the wheel bearing/hub assembly to the steering knuckle.
Notice: Refer to Fastener Notice .
2. Install the wheel bearing/hub mounting bolts.
Tighten the bolts to 130 N.m (96 lb ft).
3. Install the wheel drive shaft spindle nut.
Tighten the nut to 205 N.m (151 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 10637
4. Install the wheel speed sensor electrical connector to the mounting bracket, if equipped.
5. Connect the wheel speed sensor electrical connector. 6. Install the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
7. Install the front brake rotor. Refer to Front Brake Rotor Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Service and Repair > Front Suspension > Page 10638
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Front Wheel Drive Shaft Spindle Nut. Tighten the nut to .....................................................................
.............................................................................................................. 205 N.m (151 lb ft).
Rear Wheel Drive Shaft Nut
Important: DO NOT re-use the wheel drive shaft spindle nut. Replace with NEW.
Hand install a new wheel drive shaft spindle nut. Tighten the nut to ...................................................
.................................................................................................................................. 125 N.m (92 lb
ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Mechanical Specifications
Drive/Propeller Shaft: Mechanical Specifications
Fastener Tightening Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Mechanical Specifications > Page 10648
Drive/Propeller Shaft: Fluid Type Specifications
Sealers, Adhesives, and Lubricants
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Page 10649
Drive/Propeller Shaft: Diagrams
Driveline Disassembled Views
Driveline Disassembled Views
1 - Front Shaft 2 - Front Mounting Bolt 3 - Washer 4 - Universal Joint 5 - Snap Ring 6 - Yoke 7 Center Support Bearing Bolt 8 - Center Support Bearing 9 - Rear Shaft 10 - Universal Joint 11 Rear Flange
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications > Page 10650
Drive/Propeller Shaft: Description and Operation
Propeller Shaft Description and Operation
The propeller shaft assembly is a 2-piece design. The front shaft consists of a plunging A-type
constant velocity joint at the front and a universal joint and yoke at the rear.
The rear shaft consists of a center bearing and a center yoke, which are pressed onto the rear half
of the propshaft and retained by a snap ring. The front and rear shafts are joined together at the
yokes with a universal joint. The rear shaft attaches to the axle with a flange which is attached to
the rear shaft with a universal joint.
The center bearing provides support where the front and rear shafts mate and is bolted to the
underbody. The front constant velocity joint is bolted to the power take-off unit (PTU), and the rear
universal joint flange is bolted to the rear differential.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Propeller Shaft
Begin the system diagnosis by reviewing the following information:
* Propeller Shaft Description and Operation (See: Description and Operation)
* Transfer Case Description and Operation (See: Transfer Case/Description and Operation/NVG
900 - Transfer Case/Transfer Case Description and Operation)for the NVG 900 transfer case
Reviewing the description and operation information will help you to determine the correct symptom
diagnostic procedure when a malfunction exists. Reviewing the description and operation
information will also help you to determine if the condition described by the customer is normal
operation. Refer to Symptoms - Propeller Shaft (See: Symptom Related Diagnostic Procedures/Symptoms - Propeller Shaft) to diagnose the system and locate the procedure.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10653
Drive/Propeller Shaft: Symptom Related Diagnostic Procedures
- Symptoms - Propeller Shaft
Symptoms - Propeller Shaft
Strategy Based Diagnostics
Review the system operations in order to familiarize yourself with the system functions. Refer to
Propeller Shaft Description and Operation (See: Description and Operation) , Transfer Case
Description and Operation (See: Transfer Case/Description and Operation/Getrag 760 - Transfer
Case/Transfer Case Description and Operation) for the Getrag 760 transfer case, and Rear Drive
Axle Description and Operation (See: Differential Assembly/Description and Operation) in this
information. All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics
is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to
resolve a system problem. The diagnostic flow is the place to start when repairs are necessary. For
a detailed explanation, refer to Strategy Based Diagnosis .
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the vehicle. Refer to Checking
Aftermarket Accessories .
Important: The constant velocity (CV) joint is not serviceable. If the boot is torn or the joint is worn
or damaged, replace the propeller shaft as an assembly.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom:
- Inspect the CV joint boot for rips or cracks.
- Rotate the CV joint to inspect for binding.
- Inspect the CV joint for grease or oil leakage.
* Verify the exact operating conditions under which the concern exists. Note factors such as speed,
road conditions, ambient temperature, and other specifics.
* Compare the driving characteristics or sounds, if applicable, to a known good vehicle and make
sure you are not trying to correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system
is operating properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
* Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise)
* Knock or Clunk Noise (See: Knock or Clunk Noise)
* Scraping Noise (See: Scraping Noise)
* Squeak Noise (See: Squeak Noise)
* Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed)
Knock or Clunk Noise
Knock or Clunk Noise
Ping, Snap, or Click Noise
Ping, Snap, or Click Noise
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10654
Scraping Noise
Scraping Noise
Shudder on Acceleration at Low Speed
Shudder on Acceleration at Low Speed
Squeak Noise
Squeak Noise
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Page 10655
Drive/Propeller Shaft: Service and Repair
Propeller Shaft Replacement
Removal Procedure
1. Place the transmission in neutral (N). 2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle 3. Mark the relationship of the propeller shaft to the rear differential drive flange
and the transfer case. 4. Support the propeller shaft at the rear differential.
5. Remove the mounting bolts for the propeller shaft at the rear differential drive flange. 6. Support
propeller shaft at the transfer case.
7. Remove the mounting bolts for the propeller shaft at the transfer case. 8. Support the propeller
shaft at the center support bearing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Page 10656
9. Remove the mounting bolts for the center support bearing.
10. With the aide of an assistant, remove the propeller shaft from the vehicle.
Installation Procedure
1. Thoroughly clean the mounting bolts for center bearing and the front and rear propeller shaft
flanges. Apply threadlocker, GM P/N 89021297
(Canadian P/N 10953488), to the bolt threads
2. With the aide of an assistant, position the propeller shaft on the supports. 3. Align the reference
marks on the front and rear of the propeller shaft to the transfer case and rear differential.
4. Position the propeller shaft on the transfer case output flange. 5. Finger tighten the mounting
bolts for the propeller shaft at the transfer case output flange.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Page 10657
6. Position the center support bearing of the propeller shaft on the vehicle. 7. Finger tighten the
mounting bolts for the center support bearing.
8. Position the propeller shaft on the rear differential drive flange. 9. Finger tighten the rear
mounting bolts for the propeller shaft.
Notice: Refer to Fastener Notice .
10. Tighten the front mounting bolts for the propeller shaft.
Tighten the mounting bolts to 25 N.m (19 lb ft).
11. Tighten the mounting bolts for the center support bearing.
Tighten the mounting bolts to 25 N.m (19 lb ft).
12. Tighten the rear mounting bolts for the propeller shaft yoke to rear drive axle.
Tighten the mounting bolts to 50 N.m (37 lb ft).
13. Remove the supports for the propeller shaft. 14. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Testing and Inspection > Page 10658
Drive/Propeller Shaft: Tools and Equipment
Special Tools
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flywheel Bolt .......................................................................................................................................
....................................................... 71 N.m (52 lb ft)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
10662
Flex Plate: Service and Repair
Engine Flywheel Replacement
Removal Procedure
1. Remove the automatic transaxle. Refer to Transmission Replacement . 2. Remove the engine
flywheel bolts and flywheel. 3. Clean the engine flywheel bolt threads and bolt holes. 4. Clean and
inspect the engine flywheel.
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install the engine flywheel and bolts
Tighten bolts to 71 N.m (52 lb ft).
2. Install the automatic transaxle. Refer to Transmission Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics
Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating
Characteristics
INFORMATION
Bulletin No.: 03-07-29-004G
Date: December 15, 2010
Subject: Manual Transmission Operating Characteristics
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior
Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission
Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation
information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle).
Important Even though this bulletin attempts to cover operating characteristics of manual
transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar
vehicle and if possible, with similar mileage. Even though many of the conditions are described as
characteristics and may not be durability issues, GM may attempt to improve specific issues for
customer satisfaction.
The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that
repair attempts will not change. The following are explanations and examples of conditions that will
generally occur in all manual transmissions. All noises will vary between transmissions due to build
variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and
clutch, level of insulation, etc.
Basic Information
Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a
sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced
with clutch damper springs and dual mass flywheels. However, some speed variation will make it
through to the transmission. This can create noise as the various gears will accel and decel against
each other because of required clearances.
Cold Operation
Manual transmission operation will be affected by temperature because the transmission fluid will
be thicker when cold. The thicker fluid will increase the amount of force needed to shift the
transmission when cold. The likelihood of gear clash will also increase due to the greater time
needed for the synchronizer assembly to perform its function. Therefore when the transmission is
cold, or before it has reached operating temperature, quick, hard shifts should be avoided to
prevent damage to the transmission.
Gear Rattle
Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a
combustion knock type of noise) type noises usually occur while operating the engine at low RPMs
(lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or
while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low
engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with
the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles
without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However,
dual-mass flywheels do not eliminate all noise.
Neutral Rattle
There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to
the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles
with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with
the clutch engaged, the sudden stop of the engine will create a rapid change in angular
acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the
components, this will create a noise. This type of noise should not be heard if the clutch is released
(pedal pushed to the floor).
Backlash
Backlash noise is created when changing engine or driveline loading. This can occur when
accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and
unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle
loading, etc. and is created from the necessary clearance between all of the mating gears in the
transmission, axle(s) and transfer case (if equipped).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 10667
Shift Effort
Shift effort will vary among different style transmissions and synchronizer designs. Usually the
more heavy duty the transmission, the higher the shift effort because of the increased mass of the
components. Shift effort can also be higher in cold weather because the fluid will be thicker.
Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift
effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder
will only increase the chance of rushing past the synchronizer leading to grinding while shifting.
Non-Synchronized Gears
Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various
transmissions, along with all gears in some medium duty transmissions, may be non-synchronized.
This means there is not a mechanism to match input and output shaft speeds to allow for a smooth
shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is
attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind.
The grinding can be reduced by coming to a complete stop and pausing for a moment before
shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty
non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft
(driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other
methods. If the driver is not able to perform this function properly, there will be gear grinding with
each improperly completed shift. Driver training may be required to correct this condition. Clutch
brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a
stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a
stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the
floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle
stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The
clutch brake is intended to only be used while at a stop. Care must be taken to not activate the
clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or
missed shift.
Skip Shift
Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models
may follow) equipped with the 6-speed manual transmission have a feature referred to as a
"skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is
illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel
economy standards. The conditions for this feature are: engine coolant at normal operating
temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to
Service Information or the Owner Manual for more details.)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 10673
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 10674
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 10675
Transmission Control Module (TCM) X3 (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 10676
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10679
7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10680
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10681
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Automatic Transmission/Transaxle/Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic
Transmission/Service Fast Learn Adapts) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10682
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Automatic
Transmission/Transaxle/Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service
and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10683
1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10684
5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Automatic
Transmission/Transaxle/Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service
and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > 6T70/6T75 - Automatic
Transmission > Page 10685
the correct software and calibrations, DTC P0602 will be erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/AF33-5
- Automatic Transaxle/Transmission Adaptive Learn and Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - Differential > Control Unit, Differential Lock > Component Information > Service and Repair > Rear
Differential Clutch Control Module Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - Differential > Control Unit, Differential Lock > Component Information > Service and Repair > Rear
Differential Clutch Control Module Replacement > Page 10691
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Diagrams > Page 10697
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information > Locations > Page 10701
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 10709
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 10710
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Automatic
Transmission Electronic Component Views > Page 10711
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10714
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10715
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10720
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10721
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10722
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10723
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10724
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > AF33-5 Automatic Transaxle > Page 10725
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10726
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10727
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 10728
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10731
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10732
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10733
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10734
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair >
6T70/6T75 - Automatic Transmission > Page 10735
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10741
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10742
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10743
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain >
Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page
10744
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TRANSFER CASE FLUID Getrag 760 ................................................................................................
.......................................................................................... 0.8 liters (0.85 quarts) NVG 900 ...............
..............................................................................................................................................................
........................ 500 ml (17.0 oz)
IMPORTANT: To the bottom of the fill hole.
NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level.
Recheck fluid level after filling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications > Page 10750
Fluid - Transfer Case: Fluid Type Specifications
TRANSFER CASE (POWER TRANSFER UNIT) VERSATRAK Fluid (GM Part No. U.S. 12378514,
in Canada 88901045).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Service and Repair > NVG 900 - Transfer Case
Fluid - Transfer Case: Service and Repair NVG 900 - Transfer Case
Transfer Case Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the drain plug (1).
3. Remove the fill plug (1).
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Service and Repair > NVG 900 - Transfer Case > Page 10753
1. Clean the drain plug and apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the
threads.
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug (1).
Tighten the drain plug to 24 N.m (18 lb ft).
3. Fill the transfer case with synthetic gear lubricant GM P/N 12378514 (Canadian P/N 88901045)
to the bottom of the fill plug, or 540 ml (18.2 oz).
4. Clean the fill plug and apply adhesive GM P/N 12345493 (Canadian P/N 10953488) to the
threads. 5. Install the fill plug (1).
Tighten the fill plug to 15 N.m (11 lb ft).
6. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Service and Repair > NVG 900 - Transfer Case > Page 10754
Fluid - Transfer Case: Service and Repair Getrag 760 - Transfer Case
Transfer Case Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the drain plug (2). 3. Remove the fill plug (1).
Installation Procedure
1. Clean the drain plug.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Service and Repair > NVG 900 - Transfer Case > Page 10755
Notice: Refer to Component Fastener Tightening Notice .
2. Install the drain plug (2).
Tighten the drain plug to 39 N.m (29 lb ft).
3. Fill the transfer case with synthetic gear lubricant GM P/N 89021677 (Canadian P/N 89021678)
to the bottom of the fill plug, or 540 ml (18.2 oz). 4. Install the fill plug (1).
Tighten the fill plug to 39 N.m (29 lb ft).
5. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-04-21-002A > Jun > 09 >
Drivetrain - Fluid Leak From Transfer Case/Trans. Area
Seals and Gaskets: Customer Interest Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-04-21-002A > Jun > 09 >
Drivetrain - Fluid Leak From Transfer Case/Trans. Area > Page 10764
transmission fluid leak due to interference with the input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-04-21-002A
> Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Fluid Leak From Transfer
Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-04-21-002A
> Jun > 09 > Drivetrain - Fluid Leak From Transfer Case/Trans. Area > Page 10770
transmission fluid leak due to interference with the input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10771
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-04-21-002A Date: 090622
Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10772
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a transmission fluid leak due to interference with the
input shaft.
Seal Installation
Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Technical Service Bulletin # 08-04-21-002A Date: 090622
Drivetrain - Fluid Leak From Transfer Case/Trans. Area
TECHNICAL
Bulletin No.: 08-04-21-002A
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 10773
Date: June 22, 2009
Subject: Automatic Transmission Fluid Leak at Transfer Case Weep Hole (Replace Front Wheel
Drive Intermediate (Inner) Shaft Seal)
Models:
2008-2010 Buick Enclave 2008-2009 Chevrolet Equinox Sport 2009-2010 Chevrolet Traverse 2010
Chevrolet Equinox 2007-2010 GMC Acadia 2010 GMC Terrain 2008-2009 Pontiac Torrent GXP
2007-2009 Suzuki XL-7 2007-2010 Saturn OUTLOOK 2008-2009 Saturn VUE with 6T45/70/75
AWD/PTU Automatic Transmission (RPO MHC/MH4/MH6) for GM or AF33-5 AWD/PTU Automatic
Transmission (RPO M45) for 2007-2008 Suzuki and Getrag 760/790 Transfer Case
Supercede: This bulletin is being revised to update the information and add model years. Please
discard Corporate Bulletin Number 08-04-21-002 (07 - Transmission/Transaxle).
Condition
Some customers may comment on a red fluid leak from the transmission or transfer case area.
Technicians may find that the fluid is leaking from the transfer case/PTU weep hole farthest from
the transmission, near the passenger side.
Cause
The front wheel drive intermediate (inner) shaft seal may be leaking. Due to low ambient
temperatures with various runout conditions between the intermediate drive shaft and the input
shaft, the seal material may not properly seal automatic transmission fluid (ATF).
Correction
Replace the front wheel drive intermediate (inner) shaft seal with a new designed seal.
Important Selecting the correct replacement seal is critical due to a 2008 mid-model design update.
Use the information below to determine which seal to use. For additional information, refer to New
Product Information in the Getrag 760/790 Transfer Case category in SI.
For Acadia, Enclave, OUTLOOK and Traverse
- For vehicles built prior to VIN Breakpoint 8J217964, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 8J217964, use second design seal, P/N 19206322
(Green).
For Equinox, Terrain, Torrent and VUE
- For vehicles built prior to VIN Breakpoint 86075818, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86075818, use second design seal, P/N 19206322
(Green).
For Suzuki XL-7
- For vehicles built prior to VIN Breakpoint 86115983, use first design seal, P/N 19180998 (Green).
- For vehicles built on or after VIN Breakpoint 86115983, use second design seal, P/N 19206322
(Green).
Notice
Second design seals are not compatible with first design transfer cases. Installing a second design
seal in a first design transfer case will create a transmission fluid leak due to interference with the
input shaft.
Seal Installation
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
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Installing the replacement seal to the proper depth is critical. Use the DT-48078 - Inner Drive Shaft
Seal installer with a J 8092 - Driver Handle to install the seal 2.8 mm (0.11 in) (a) from the end of
the input shaft. Refer to the Front Drive Axle Inner Shaft Seal Replacement procedure in SI.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case >
System Information > Technical Service Bulletins > Page 10775
Seals and Gaskets: Service and Repair
Axle Shaft Oil Seal Replacement
Tools Required
* J 38868 Output Shaft Assembly Remover and Installer
* J 44809 Output Shaft Seal Installer
* J 6125-1B Slide Hammer with Adapter
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the right
wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and
Joints/Axle Shaft
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
3. Remove the retainer ring from the stub shaft for tool installation. Discard the used retainer ring.
4. Remove the stub shaft using the J 6125-1B and J 38868 .
5. Carefully, remove the output shaft seal and discard.
Installation Procedure
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System Information > Technical Service Bulletins > Page 10776
1. Clean any dirt or foreign material from the seal bore area. 2. Using the J 44809 , install the NEW
output shaft seal.
3. Install the stub shaft using the J 6125-1B and J 38868 . 4. Install a NEW retainer ring on the stub
shaft. 5. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (See:
Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Front Wheel Drive Shaft Replacement) .
6. Remove the fluid fill plug and check the fluid level. Fluid should be to the bottom of the fill hole
threads. Add synthetic gear lubricant GM P/N
12378514 (Canadian P/N 88901045) if necessary.
7. Clean and fill plug and apply adhesive GM P/N 12345493 (Canadian P/N 10953488) to the
threads.
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System Information > Technical Service Bulletins > Page 10777
Notice: Refer to Fastener Notice .
8. Install the fill plug (1).
Tighten the fill plug to 15 N.m (11 lb ft).
9. Lower the vehicle.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
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Information > Locations > Page 10784
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Locations
Shift Interlock Solenoid: Locations
Instrument Panel/Center Console Component Views
Shift Lever Components
Below The Shifter
1 - Instrument Panel Trim 2 - Console Arm Rest 3 - Cigar Lighter 4 - Shift Lock Control Solenoid
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Locations > Page 10788
Shift Interlock Solenoid: Diagrams
Component Connector End Views
Automatic Transmission Shift Lock Control Solenoid
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Specifications > AF33-5 - Automatic Transaxle
Shift Solenoid: Specifications AF33-5 - Automatic Transaxle
Shift Solenoid Valve State and Gear Ratio
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Specifications > AF33-5 - Automatic Transaxle > Page 10793
Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission
Shift Solenoid Valve State and Gear Ratio
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle
Shift Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10796
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10797
Shift Solenoid: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
AF33-5 - Automatic Transaxle > Page 10798
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Diagram Information and Instructions > Page 10801
Shift Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagram Information and Instructions > Page 10802
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Diagram Information and Instructions > Page 10803
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Diagram Information and Instructions > Page 10804
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagram Information and Instructions > Page 10805
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Diagram Information and Instructions > Page 10806
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Diagram Information and Instructions > Page 10807
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Diagram Information and Instructions > Page 10808
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Diagram Information and Instructions > Page 10884
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Diagram Information and Instructions > Page 10885
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Diagram Information and Instructions > Page 10886
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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Diagram Information and Instructions > Page 10887
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Diagram Information and Instructions > Page 10888
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Diagram Information and Instructions > Page 10889
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 10890
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 10891
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Diagram Information and Instructions > Page 10892
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagram Information and Instructions > Page 10895
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagram Information and Instructions > Page 10896
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 10899
Shift Solenoid: Connector Views
Component Connector End Views - Continued
Shift Solenoid 1 (AF33-5)
Shift Solenoid 2 (AF33-5)
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Shift Solenoid 3 (AF33-5)
Shift Solenoid 4 (AF33-5)
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Shift Solenoid 5 (AF33-5)
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Diagram Information and Instructions > Page 10903
Shift Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
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Page 10904
Shift Solenoid: Service and Repair
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly. 7.
Remove the 2 control valve body bolts (4) M6 x 65.
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8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6
x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
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Page 10906
2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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Page 10907
11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Automatic Transmission/Transaxle/Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic
Transmission/Service Fast Learn Adapts) .
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Information > Locations > AF33-5 - Automatic Transaxle
Torque Converter Clutch Solenoid: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
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308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
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Torque Converter Clutch Solenoid: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
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Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
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22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
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Torque Converter Clutch Solenoid: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Torque Converter Clutch Solenoid: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information > Diagrams > Diagram Information and Instructions > Page 11010
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 11011
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information > Diagrams > Diagram Information and Instructions > Page 11012
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Information > Diagrams > Diagram Information and Instructions > Page 11013
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information > Diagrams > Diagram Information and Instructions > Page 11014
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Information > Diagrams > Diagram Information and Instructions > Page 11015
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Information > Diagrams > Diagram Information and Instructions > Page 11016
Torque Converter Clutch Solenoid: Connector Views
Component Connector End Views - Continued
Torque Converter Clutch (TCC) Lock Up Pressure Control Solenoid (SLU) (AF33-5)
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Information > Diagrams > Diagram Information and Instructions > Page 11017
Torque Converter Clutch Solenoid: Electrical Diagrams
AF33-5 - Automatic Transaxle
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
6T70/6T75 - Automatic Transmission
For information regarding diagrams for this system, please refer to Transmission Control Systems
diagrams. See: Diagrams/Electrical Diagrams
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations
Control Module: Locations
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5) 308 - 2-3, 3-4 Shift Solenoid Valve
Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve Assembly (S1)
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Page 11023
316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up Pressure Control
Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve Assembly (SLS)
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Page 11024
Control Module: Diagrams
Component Connector End Views - Continued
Transmission Control Module (TCM) X1 (AF33-5)
Transmission Control Module (TCM) X2 (AF33-5)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Page 11025
Transmission Control Module (TCM) X3 (AF33-5)
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Page 11026
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > 6T70/6T75 - Automatic Transmission
Control Module: Service and Repair 6T70/6T75 - Automatic Transmission
Control Solenoid Valve and Transmission Control Module Assembly Replacement
Removal Procedure
1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See:
Automatic Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed
sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3).
5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring
(8) to the side. Spring will be released with the removal of the control valve body assembly.
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7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6
x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95.
10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body
and transmission control module (TCM) assembly (5).
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
12. Remove the control solenoid valve assembly filter plate (6).
* Discard the filler plate. It is not reusable.
* Inspect the pressure switch manifold seals for damage or contamination. Replace the control
solenoid valve assembly as necessary.
* Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage
around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage
around the PCS seals. Replace the upper channel plate as necessary.
Installation Procedure
Notice: Use care when removing or installing the filter plate assembly. A broken or missing
retaining tab may not adequately secure the filter plate to the control solenoid valve assembly,
resulting in possible damage or contamination.
1. Install a NEW control solenoid valve assembly filter plate (1).
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2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid
valve spring (7) into position.
Notice: Refer to Fastener Notice .
Important: Install all bolts before tightening, then tighten in specified sequence.
4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x
55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6
x 42. 8. Install the 2 control valve body bolts (4) M6 x 65.
Tighten the bolts in sequence to 12 N.m (106 lb in).
9. Connect the input speed sensor electrical connector (1).
10. Connect the output speed sensor electrical connector (2).
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11. Connect the shift position switch electrical connector (3). 12. Install the control valve body
cover. Refer to Control Valve Body Cover Replacement (See: Automatic
Transmission/Transaxle/Valve
Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover
Replacement) .
13. For transmission control module programming and setup. Refer to Control Module References .
Important: After an internal transmission repair or internal part replacement the service fast learn
adapt procedure should be performed.
14. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See:
Automatic Transmission/Transaxle/Testing and
Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic
Transmission/Service Fast Learn Adapts) .
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Repair > 6T70/6T75 - Automatic Transmission > Page 11032
Control Module: Service and Repair AF33-5 - Automatic Transaxle
Transmission Control Module Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
Important: The transaxle manual shaft must be in neutral (N) position prior to re-installing the
transmission control module (TCM).
2. Apply the parking brake and place control shift lever in neutral (N).
3. Remove the manual shaft detent lever (2). Refer to Automatic Transmission Range Selector
Lever Replacement (See: Sensors and Switches Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Position
Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
4.
Disconnect the electrical connectors from the TCM.
5. Remove the TCM bolts (3). 6. Remove the TCM (4) by sliding off of the manual shaft.
Installation Procedure
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1. Using an adjustable wrench on the manual shaft detent lever (710), turn the shaft clockwise until
it stops. 2. Turn the shaft counterclockwise one position to the neutral location. To verify turning the
shaft in the correct direction, on the manual shaft detent
lever (710) the reverse position is larger and more resistance can be felt.
3. Inspect the condition of the connector pins on the wiring harness assembly (33) for foreign
material, bent pins, or broken pins. 4. Ensure the TCM seal (72) is installed.
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5. Turn the slot in the TCM to align the 2 marks. Do not turn more than 60 degrees.
6. Install the TCM (4) over the manual shaft.
Notice: Refer to Fastener Notice .
7. Install the bolts (3).
Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the electrical connectors (3, 5) to the TCM. 9. Install the manual shaft detent lever.
Refer to Automatic Transmission Range Selector Lever Replacement (See: Sensors and Switches
Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Position
Switch/Sensor/Service and Repair/AF33-5 - Automatic Transaxle) .
10. Install the battery tray. Refer to Battery Tray Replacement .
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Important: DTC P0602 is set with all new service transaxle control modules. When the transaxle
control module is reprogrammed with the correct software and calibrations, DTC P0602 will be
erased.
11. Reprogram the TCM with the correct calibration. Refer to Control Module References . 12.
Perform the transmission adaptive learn procedure. Refer to Transmission Adaptive Learn and
Transmission Neutral Learn (See: Automatic
Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/AF33-5
- Automatic Transaxle/Transmission Adaptive Learn and Transmission Neutral Learn) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Differential > Control Unit, Differential Lock > Component Information >
Service and Repair > Rear Differential Clutch Control Module Replacement
Control Unit: Service and Repair Rear Differential Clutch Control Module Replacement
Rear Differential Clutch Control Module Replacement
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Differential > Control Unit, Differential Lock > Component Information >
Service and Repair > Rear Differential Clutch Control Module Replacement > Page 11041
Control Unit: Service and Repair Rear Wheel Drive Module Clutch Housing Replacement
Rear Wheel Drive Module Clutch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Diagrams
Fluid Pressure Sensor/Switch: Diagrams
Component Connector End Views - Continued
Line Pressure Control Solenoid (SLT) (AF33-5)
Shift Pressure Control Solenoid (SLS)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information >
Diagrams > Page 11047
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information >
Locations
Lateral Acceleration Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Lateral Acceleration Sensor, A/T > Component Information >
Locations > Page 11051
Lateral Acceleration Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Transmission Mode Switch: Diagrams
Component Connector End Views - Continued
Internal Mode Switch (IMS) (6T70)
Internal Mode Switch (IMS)
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Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Automatic Transmission Electronic Component Views
Transmission Position Switch/Sensor: Locations Automatic Transmission Electronic Component
Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
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Information > Locations > Automatic Transmission Electronic Component Views > Page 11059
Transmission Position Switch/Sensor: Locations Park System Components
Disassembled Views
Park System Components
Park System Components
500 - Park Pawl Actuator Bracket Bolt 501 - Park Pawl Actuator Bracket 502 - Park Pawl Shaft 503
- Park Pawl 504 - Park Pawl Spring 505 - Park Pawl Actuator Guide Pin 506 - Park Pawl Actuator
Guide 507 - A/Trans Case Assembly 508 - Manual Shift Shaft Seal 509 - Park Pawl Actuator
Assembly 510 - Manual Shift Shaft Pin 511 - Manual Shift Detent (w/Shaft Position Switch) Lever
Assembly
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Information > Locations > Automatic Transmission Electronic Component Views > Page 11060
Transmission Position Switch/Sensor: Locations Component Location
Component Location
Component Locations
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear
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Information > Locations > Automatic Transmission Electronic Component Views > Page 11061
15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front
Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear
20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and
Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case
Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve
Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual
Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Position Switch/Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Manual Shift Detent Lever and Shaft Position Switch Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11064
Transmission Position Switch/Sensor: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Range Selector Lever Replacement
Tools Required
J 36346 Fascia Retainer Remover
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement . 2. Ensure that the shift control
range select lever is in the park (P) position.
3. Using the J 36346 , disconnect the shift control cable (1) from the transaxle range switch lever
(4). 4. Depress the shift control cable retainer clip tabs (2) and remove the shift control cable from
the shift control cable bracket (3).
5. Remove the transaxle range selector lever nut and lever.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11065
Notice: Refer to Fastener Notice .
1. Install the transaxle range selector lever and lever nut.
Tighten the nut to 16 N.m (12 lb ft).
2. Install the shift control cable (2) to the shift control cable bracket (3). Ensure the shift control
cable retaining tabs fully engage the shift control
cable bracket.
3. Connect the shift control cable (1) to the transaxle range switch lever (4). 4. Install the battery
tray. Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle
Transmission Speed Sensor: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11070
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11071
Transmission Speed Sensor: Locations 6T70/6T75 - Automatic Transmission
Automatic Transmission Electronic Component Views
Automatic Transmission Electronic Component Views
Electronic Components
Electronic Components
15 - Control Solenoid (w/Body and TCM) Valve Assembly 19 - A/Trans Output Speed Sensor
Assembly 400 - A/Trans Input Speed Sensor Assembly 511 - Manual Shift Detent (w/Shaft Position
Switch) Lever Assembly
Component Location
Component Location
Component Locations
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11072
Component Location
1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier
Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear
Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid
Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front
Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump
Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch
Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11073
22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch
Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor
28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor
Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM)
35 - Manual Valve
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11074
Transmission Speed Sensor: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > AF33-5 - Automatic Transaxle > Page 11075
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 11076
Transmission Speed Sensor: Diagrams
Component Connector End Views - Continued
Input Shaft Speed (ISS) Sensor Connector, Wiring Harness Side (AF33-5)
Input Speed Sensor (ISS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 11077
Output Shaft Speed (OSS) Sensor, Wiring Harness Side (AF33-5)
Output Speed Sensor (OSS) (6T70)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Page 11078
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission
Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11081
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11082
Transmission Speed Sensor: Service and Repair AF33-5 - Automatic Transaxle
Input Speed Sensor Replacement
Input Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray . Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (4) from the input speed sensor.
3. Remove the input speed sensor bolt. 4. Remove the input speed sensor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11083
5. Remove the input speed sensor O-ring. Discard the O-ring.
Installation Procedure
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new input speed sensor
O-ring. 2. Install the new input speed sensor O-ring onto the input speed sensor. 3. Install the input
speed sensor to the transaxle.
Notice: Refer to Fastener Notice .
4. Install the input speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (4) to the input speed sensor. 6. Install the battery tray . Refer
to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11084
Output Speed Sensor Replacement
Output Speed Sensor Replacement
Removal Procedure
1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Disconnect the electrical connector (2) from the output shaft speed sensor.
3. Remove the output speed sensor bolt. 4. Remove the output shaft speed sensor and the O-ring.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > 6T70/6T75 - Automatic Transmission > Page 11085
1. Apply GM T-IV automatic transaxle fluid GM P/N 88900925 to the new output speed sensor
O-ring. 2. Install the new output speed sensor O-ring onto the output speed sensor (2). 3. Install the
output speed sensor into the transmission case assembly.
Notice: Refer to Fastener Notice .
4. Install the output speed sensor bolt.
Tighten the bolt to 6 N.m (53 lb in).
5. Connect the electrical connector (2) to the output shaft speed sensor. 6. Install the battery tray.
Refer to Battery Tray Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
Transmission Fluid Temperature Sensor Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle
Transmission Temperature Sensor/Switch: Locations AF33-5 - Automatic Transaxle
Automatic Transmission Electronic Component Views
Electronic Components View
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Automatic Transmission Output
Speed Sensor 73 - Automatic Transmission Input Speed Sensor 75 - Transmission Control Module
(TCM) 300 - 1-2, 2-3, Reverse, Shift Solenoid Valve Assembly (S3) 303 - 3-4, 4-5 Shift Solenoid
Valve Assembly (S4) 305 - Reverse Shift Valve Solenoid (S5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 11091
308 - 2-3, 3-4 Shift Solenoid Valve Assembly (S2) 310 - Reverse, 1st Shift Solenoid Valve
Assembly (S1) 316 - Line Pressure Control Solenoid Valve Assembly (SLT) 339 - TCC Lock Up
Pressure Control Solenoid Valve Assembly (SLU) 340 - Shift Pressure Control Solenoid Valve
Assembly (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 11092
Transmission Temperature Sensor/Switch: Locations Powertrain Component Views
Powertrain Component Views
Automatic Transmission Electronic Components (LNJ)
Electronic Components View
36 - Automatic Transmission Fluid Temperature Sensor 62 - Output Shaft Speed Sensor 73 - Input
Shaft Speed Sensor 75 - Transmission Control Module (TCM) 300 - Shift Solenoid 3 303 - Shift
Solenoid 4 305 - Shift Solenoid 5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > AF33-5 - Automatic Transaxle > Page 11093
308 - Shift Solenoid 2 310 - Shift Solenoid 1 316 - Line Pressure Control Solenoid (SLT) 339 - TCC
Pressure Control Solenoid (SLU) 340 - Shift Pressure Control Solenoid (SLS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations > Page 11094
Transmission Temperature Sensor/Switch: Diagrams
Component Connector End Views
Automatic Transmission Fluid Temperature (TFT) Sensor (AF33-5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 11105
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 11106
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 11107
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign
- ESC/Steering Module Reprogramming > Page 11108
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep >
07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep >
07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 11114
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 11120
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11125
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11126
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11127
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11128
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page
11134
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11140
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11141
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11142
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic
Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11143
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 11144
Electronic Brake Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 11145
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 11146
Electronic Brake Control Module (EBCM) (Pin 1 To 35)
Electronic Brake Control Module (EBCM) (Pin 36 To 47)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 11147
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 11148
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Replacement
Brake Pressure Modulator Valve Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement > Page 11153
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic
Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve
Replacement > Page 11154
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Bracket Replacement
Brake Pressure Modulator Valve Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Angle Sensor Centering
The steering angle sensor does not require centering often. Centering of the steering angle sensor
might be required after certain service procedures are performed. Some of these procedures are
as follows:
* Steering gear replacement
* Steering column replacement
* Steering angle sensor replacement
* Intermediate shaft replacement
* Antilock brake system (ABS) controller replacement
* Collision or other physical damage
The steering angle sensor centering procedure can be preformed with a scan tool in the automated
center procedure by the following:
1. Using the steering wheel, align the front wheels forward. 2. Set the transmission in the PARK
position. 3. Install the scan tool to the data link connector (DLC). 4. Turn the ignition switch ON,
with the engine OFF. 5. Select Chassis/EBCM control system vehicle stability enhancement
system (VSES), special function test, and Steering Pos. Sensor Calibration. 6. Follow the scan tool
directions to complete the automated centering procedure this should include turning the steering
wheel left 5 degrees and
right 5 degrees and then straight forward.
7. Clear any DTCs that may be set. Perform the Diagnostic System Check to verify no current
DTCs. Refer to Diagnostic System Check - Vehicle . 8. Centering of the steering angle sensor is
complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Locations
Traction Control Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Locations > Page 11161
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Locations > Page 11162
Traction Control Switch: Diagrams
Component Connector End Views - Continued
Traction Control Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Locations > Page 11163
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
2. Carefully release the retaining tabs and remove the traction control switch from the trim bezel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction
Control Switch > Component Information > Locations > Page 11164
1. Install the traction control switch to the trim bezel. Ensure that the retaining tabs are fully
engaged.
2. Install the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Left Front Suspension Components
1 - X103 Left Shown, X104 Right Similar 2 - Wheel Speed Sensor (WSS) - Left Front, Right Front
Similar
Rear Axle Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 11168
1 - Rear Cradle 2 - Wheel Speed Sensor (WSS) - Left Rear 3 - Wheel Speed Sensor (WSS) - Right
Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 11169
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 11170
Wheel Speed Sensor - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Page 11171
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 11174
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 11178
Yaw Rate Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate
Sensor > Component Information > Locations > Page 11179
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important: Before performing the antilock brake system (ABS) Automated Bleed Procedure, first
perform a manual or pressure bleed of the base brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) . The automated
bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out toward the brake corners.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove all 4 tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic
System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or
replace components as needed.
4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test . 6.
Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish
communications with the ABS system. Select Special Functions. Select Automated Bleed from the
Special Functions
menu.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed
procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed
procedure:
* If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle , and diagnose the
appropriate DTC.
* If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to
Hydraulic Brake System Bleeding (Manual) ( See: )Hydraulic Brake System Bleeding (Pressure)
(See: ) .
13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14.
Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation . 17. Inspect the brake fluid level. Refer to Master
Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Procedures/Master Cylinder Reservoir Filling) .
18. Road test the vehicle while inspecting that the pedal remains high and firm.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 11184
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding
procedure. Add fluid as needed to maintain the proper
level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress
the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant
slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all
air has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 11185
20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
21. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 44894-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster
power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532 ,
or equivalent, to the J 44894-A . 7. Charge the J 29532 , or equivalent, air tank to 175-205 kPa
(25-30 psi). 8. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to
enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake
system in order to ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the
bleeder, then
tighten the bleeder valve.
13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 11186
17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
20. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent,
from the J 44894-A . 21. Remove the J 44894-A from the brake master cylinder reservoir. 22.
Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake
pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Hydraulic System/Testing and
Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) .
2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake
System Automated Bleed Procedure (See: ) .
24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
25. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Hydraulic System/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 11187
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance-Oil-based substance
- Layered appearance-Silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance-Moisture
- Dark appearance/suspended particles in fluid-Dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Reservoir Replacement (See: Hydraulic System/Brake Master Cylinder/Service
and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement)
* Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic
System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder
Reservoir Replacement) . Replace the brake master cylinder reservoir cap diaphragm.
* Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Front Brake Hose Replacement)
* Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and
Repair/Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and
Repair/Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control
Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Antilock Brake System Automated Bleed Procedure > Page 11188
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may
have allowed the moisture or particles to enter the hydraulic system.
5. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair
Brake Pedal Assy: Service and Repair
Brake Pedal Assembly Replacement
Removal Procedure
1. Disconnect the accelerator pedal assembly electrical connector.
2. Remove the retaining clip and washer from the brake pedal. 3. Release the brake booster
pushrod from the brake pedal. 4. Disconnect the brake pedal position sensor electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 11192
5. Remove the brake pedal bracket-to-steering column bracket bolt.
6. Remove the brake booster mounting nuts. 7. Position the brake booster forward to clear the
studs from the front of the dash.
8. Loosen, but do not remove, the steering column bracket to cowl nut. 9. While simultaneously
disengaging the brake pedal bracket pilot bushings from the foam insulation panel, pull the brake
pedal assembly back and
toward the center of the vehicle.
10. Remove the brake pedal assembly from the vehicle.
11. Remove the accelerator pedal assembly from the brake pedal bracket. Refer to Accelerator
Pedal Position Sensor Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 11193
Installation Procedure
1. Install the accelerator pedal assembly to the brake pedal bracket. Refer to Accelerator Pedal
Position Sensor Replacement .
2. Install the brake pedal assembly into the vehicle, while guiding the brake pedal bracket pilot
bushings into the foam insulator panel. 3. Position the booster studs through dash panel.
Notice: Refer to Fastener Notice .
4. Install the brake pedal bracket-to-steering column bracket bolt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 11194
Tighten the bolt to 25 N.m (18 lb ft).
5. Loosely install the brake booster mounting nuts. 6. Apply a thin coating of lithium grease to the
pushrod pin on the brake pedal.
7. Connect the brake booster pushrod to the brake pedal. 8. Install the washer and retaining clip to
the brake pedal.
9. Tighten the vacuum brake booster mounting nuts.
Tighten the nuts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and
Repair > Page 11195
10. Install the steering column bracket to cowl nut.
Tighten the nuts to 25 N.m (18 lb ft).
11. Connect the brake pedal position sensor electrical connector.
12. Connect the accelerator pedal assembly electrical connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information
Brake Caliper: Technician Safety Information
Caliper Piston Removing Caution
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information > Page 11201
Brake Caliper: Vehicle Damage Warnings
Brake Caliper Notice
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service Precautions > Page 11202
Brake Caliper: Testing and Inspection
Brake Caliper Inspection
Caution: Refer to Brake Dust Caution . Caution: Refer to Brake Fluid Irritant Caution .
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper piston, or pistons, into the caliper bore, or
bores:
The movement of a caliper piston into a caliper bore should be smooth and even. If a caliper piston
is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement
Brake Caliper: Service and Repair Front Brake Caliper Replacement
Front Brake Caliper Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11205
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11206
Brake Caliper: Service and Repair Rear Brake Caliper Replacement
Rear Brake Caliper Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11207
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11208
Brake Caliper: Service and Repair Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11209
Brake Caliper: Service and Repair Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11210
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Rear Brakes
Brake Pad Lining Minimum Thickness
................................................................................................................................................ 2.0 mm
(0.080 in)
Front Brakes
Brake Pad Lining Minimum Thickness
................................................................................................................................................ 2.0 mm
(0.080 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Page 11214
Brake Pad: Testing and Inspection
Brake Pad Inspection
Caution: Refer to Brake Dust Caution .
* Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are
removed from the vehicle.
* If replacement is necessary, always replace disc brake pads in axle sets.
* Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally
occurs at the trailing edge of the disc brake pads.
* Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn
excessively. The disc brake pad wear should be approximately even per axle set.
* Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake
pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor
(2). The wear indicator will then produce an audible, high-pitched warning noise during wheel
rotation.
* Replace the disc brake pads when the friction surface (3) is worn to within 2 mm (0.080 in) of the
mounting plates.
* Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake
pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure
the gap between the surfaces. If more than 0.5 mm (0.020 in) gap exists midway between the
length of the disc brake pads, replace the disc brake pads.
* Verify that any disc brake pad shims that may be required are in place and not damaged or
excessively corroded. Replace any missing or damaged shims in order to preserve proper disc
brake performance.
* Replace the disc brake pads if any have separated from the mounting plates.
* Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause
noise or otherwise impair disc brake performance.
* Inspect the noise insulators on the brake pad mounting plate. Replace the brake pads if the noise
insulators have separated from the brake pad mounting plate.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement
Brake Pad: Service and Repair Front Disc Brake Pads Replacement
Front Disc Brake Pads Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 11217
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 11218
Brake Pad: Service and Repair Rear Disc Brake Pads Replacement
Rear Disc Brake Pads Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 11219
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front Disc Brake Pads Replacement > Page 11220
Brake Pad: Service and Repair Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing
Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.
Caution: Refer to Brake Dust Caution .
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures
Technical Service Bulletin # 00-05-22-002L Date: 090326
Brakes- Disc Brake Warranty Service And Procedures
INFORMATION
Bulletin No.: 00-05-22-002L
Date: March 26, 2009
Subject: Disc Brake Warranty Service and Procedures
Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2
2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X
(Canada Only) 1999-2010 Saturn Vehicles (Canada Only)
EXCLUDING 2009-2010 Chevrolet Corvette ZR1
Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake
corner and wheel design, assembly plant build processes and dealership required tools like the
On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing
base brake service. Due to this change, you are no longer required to enter the LRO measurement
on the repair order or in the warranty system failure code section. The bulletin information below
and the base brake labor operations have been updated accordingly. Due to this change it is more
important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration
Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes).
For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service
Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional
information, the Service Technical College lists a complete index of available Brake courses. This
information can be accessed at www.gmtraining.com > resources > training materials > brakes
courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake
Certification program 15003.16H.
Important
PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR
NEXT GM BRAKE SERVICE.
The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a
successful brake service.
1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace
2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel
3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness
(REQUIRED on Repair Order)
Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly
calibrated.
4. Properly reassemble the brake corner using proper torque tools, torque specification and torque
sequence - wheel lug nuts.
* The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after
refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec
after refinish and not the discard spec.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11225
Bulletin Format
***REPAIR ORDER REQUIRED DOCUMENTATION
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11226
Important
When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake
Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor
Thickness are required and MUST be written/documented on the repair order, or for your
convenience, complete the form (GM Brake Service Repair Order Documentation for Required
Measurements) shown above and attach it to the repair order. If the Warranty Parts Center
generates a request, this Documentation/Form must be attached to the repair order that is sent
back.
Important
Documentation of brake lathe maintenance and calibration as recommended by the lathe
manufacturer must be available for review upon request.
Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED
When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before
refinish) and REFINISHED thickness (measured thickness after refinish) MUST be
written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is
necessary, only the original thickness measurement needs to be recorded.
Repair Order Documentation - Explanation of Part Replacement - REQUIRED
If replacement of a brake component is necessary, proper documentation on the repair order is
required. See the following examples:
^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a
prior brake service. After rotor measurement, it was determined that refinishing the rotor again
would take it under the Minimum Thickness specification.
^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads
contaminated by fluid leak at caliper.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11227
TOOL INFORMATION
CORRECTION PLATE PART INFORMATION
Refer to TSB 01-05-23-001 for the Brake Align(R) application chart.
For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be
submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are
available through the following suppliers:
- Dealer Equipment and Services
- Brake Align(R) LLC (U.S. Dealers Only)
* We believe this source and their products to be reliable. There may be additional manufacturers
of such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from this firm or for any such items, which may be available from
other sources.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11228
WARRANTY INFORMATION
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11229
WORKSHEET - BRAKE LATHE CALIBRATION
Important
Brake lathe calibration should be performed and recorded monthly or if you are consistently
measuring high LRO after rotor refinishing.
Disclaimer
GM Brake Service Procedure
GM BRAKE SERVICE PROCEDURE
1. Remove the wheel and caliper.
2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following
steps:
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11230
If performing routine Brake Service for worn pads only, and the rotors are not damaged and
measure within specification - DO NOT REFINISH ROTORS.
1. Remove the rotor(s).
2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points
should be taken and the lowest measurement
should be recorded.
3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for
Minimum Thickness specification/other. In
most cases, the rotor should be refinished unless the measurement taken makes it obvious that
refinishing the rotor would take the measurement under the Minimum Thickness specification (then
replacement is necessary). DO NOT use any other manufacturers rotor specifications.
3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as
noted in the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz
Wheel(R).
If rotors are not to be refinished - Go To Step 8.
Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris
(which includes removal of Hubless rotors) is critical and MUST be performed whether using an
On-Car or Bench Lathe Refinish Procedure.
5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are
using.
Important Only replace the rotors if they do not meet the Minimum Thickness specification.
Important DO NOT REFINISH NEW ROTORS.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with
the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut.
Bench Type Lathe
1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of
debris or burrs. For more information, see the
"Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin.
3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools
into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a
full turn
4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
7. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
On-Car Type Lathe
1. Reinstall the rotor(s).
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11231
When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is
critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe.
Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating
driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep
their body out of the wheel well area until the machine has reached its normal operating RPM.
2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and
parallel surfaces.
Important When raising the vehicle on the lift, be sure to have it at a good working height (waist
high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the
lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming
out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time
of the lathe.
3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the
vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb
ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the
adapter.
Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor
retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface.
4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for
run-out in the hub.
5. Once the computer indicates the compensation process was successful, on the outboard area of
the rotor, position the cutting tools one eighth
of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the
rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same
procedure. If zero is passed during the process, reset zero.
8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters
to the zero setting plus just enough to clean up the entire rotor surface.
9. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit
sandpaper to obtain a non-directional finish.
10. Dismount the lathe, but leave the lathe adapter attached to the vehicle.
6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish
washing soap) or wipe it clean with GM approved
brake cleaner, P/N 88862650 (Canadian P/N 88901247).
Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as
a by-product of machining to the pad material during the seating process, thus reducing the
opportunity for squeaks or other noises to occur.
7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer
to the "Repair Order Documentation - Rotor
Refinish" section of this bulletin.
8. Setting up to measure for Lateral Run Out (LRO):
Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these
steps are being left in the overall procedure as a good check to be performed in the case of a
repeat pulsation complaint. If you are not checking for LRO, go to step 16.
Bench-Type Lathe
1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean
and free of debris.
2. Mount the new, original or refinished rotor onto the vehicle hub.
Important Always hold the rotor on the bottom half so any debris that may be dislodged from the
vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor
falling over on the studs can release rust from the vents on the rotor.
3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto
the studs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11232
4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical
washers (with the tapered hole side facing
out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it.
5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start
and snug the lug nuts by hand.
6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with
the lug nut opposite of the one you first
tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not
completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the
lug nuts in a star pattern to the specific vehicle torque specification.
7. DO NOT reinstall the caliper or the wheel at this time.
On-Car Type Lathe
1. Leave the On-Car adapter on the wheel.
2. Proceed to Step 9.
9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor
outboard friction surface approximately 6.35 mm
(0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of
the rotor.
Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false
readings.
10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification
(0.050 mm (0.002 in) or LESS).
1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is
indicated and set the dial indicator to zero.
2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading
(rotor "high spot"). Note the amount and mark
the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location.
If the high point falls between two studs, mark both studs. In instances where the vehicle has
"capped lug nuts" you should mark the hub.
11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is
necessary. Go to Step 15 if this is the first rotor
completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050
mm (0.002 in), go to Step 12.
12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to
correct for LRO:
Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of
the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of
LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure").
Hubless Rotor
1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B),
choose the correct plate to bring the rotor
LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006
in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the
instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B.
2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high
spot") or between the two points marked (if
the "high spot" is between two wheel studs).
Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer
to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO.
Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates
together on one hub. NEVER attempt to reuse a previously installed Correction Plate.
3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8.
Make sure to index the rotor correctly to the
marks made in step 10, otherwise LRO will be comprised.
Hubbed / Captured / Trapped Rotor
1. Measure the rotor thickness.
2. Refinish or replace the rotor (see Service Information for further details).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11233
13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification.
14. If using,
BENCH LATHE - DO NOT remove conical washers and lug nuts at this time.
ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain
rotor position.
Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the
hub and install the top conical washer and lug nut first to ensure no debris falls between the
surface while removing the adapter. Then, install the remaining conical washers and lug nuts.
Otherwise, LRO will be comprised.
15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO).
16. Reinstall the rotors on both sides of the vehicle and perform the following steps:
1. Reinstall the calipers and pads.
2. Pump the brakes to pressurize the calipers.
3. Remove the lug nuts/conical washers.
4. Install and properly torque the wheels.
Important It is critical to follow the star pattern wheel torque procedure and use the proper tools
(torque stick or torque wrench) as referenced in SI.
17. Road test the vehicle to verify the repairs.
Brake Lathe Calibration Procedure
BRAKE LATHE CALIBRATION PROCEDURE
Calibration of the brake lathe should be performed and recorded monthly or whenever post-service
brake rotor LRO measurements are consistently reading above specification.
BENCH-TYPE LATHE
Use the following procedure to calibrate a Bench-type brake lathe:
1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it
from rotating, rotate the rotor 180 degrees.
2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as
checking the run out on the vehicle.
3. Rotate the arbor and read the runout.
4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the
rotor.
Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe
(this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an
On-Car type lathe).
Machining the Inside Bell Clamp (Bench Type Lathe Only)
Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to
accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat
against the shoulder surface using slight pressure. When the burrs are gone, clean the surface.
Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with
the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing
the burrs, clean the hub.
Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then
spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool
bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the
face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360
degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and
line up these marks before machining a rotor. A magic marker can be used to make the match
marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell
Clamps used.
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11234
Important
If runout is still present, contact the brake lathe supplier.
ON-CAR TYPE LATHE
Use the following procedure to calibrate an On-Car brake lathe:
1. Connect the lathe to a vehicle using the appropriate adapter.
2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a
flat surface on the cutting head.
3. Turn on the lathe and press the "start" button so the lathe begins to compensate.
4. Once compensation is complete, note the runout as measured by the dial indicator. Measured
runout at this point is overstated given that it is
outside the rotor diameter.
5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor
diameter), calibration must be tightened. Follow
manufacturer's instructions for tightening the calibration of the lathe. This information is found in the
manual supplied with the lathe.
Important If the machine is taking a long time to compensate during normal use, prior to checking
the lathe calibration, it is recommended that the machine be disconnected from the adapter and the
adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will
accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will
change the location of the runout (phase) relative to the machine and thus possibly allow for quick
compensation as a result of the position change.
The following information has been added as a reference to ensure your Pro-Cut PFM lathe
provides a consistent smooth surface finish over long term usage.
Cutting Tips / Depth of Cut / Tip Life
The cutting tips must be right side up. Reference marks always face up. The cutting tips may not
have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will
provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits,
make sure that the seat area for the tip on the tool is free and clear of debris.
Cutting Head
On each brake job, the technician must center the cutting head for that particular vehicle using one
of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the
technician use one hand to push the head firmly and squarely back into the dovetail on the slide
plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do
this could result in chatter occurring during the cut.
Tool Holder Plate (Cutting Head)
The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a
technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts
of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not
cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder
plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head
from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder
plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide
plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting
arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will
show itself by having the back of the cutting arm lifting off the surface of the tool holder.
Gib Adjustment / Loose Gib
As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do
this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment
process, which you should perform when required after monthly checks or whenever surface finish
is inconsistent.
Brake Pulsation
BRAKE PULSATION
Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes
the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The
"pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may
result from two basic conditions:
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11235
1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner
assembly is virtually undetectable unless measured
(with a dial indicator after the brake service) and will not be detected as brake pulsation during an
after brake service test drive. If the brake corner is assembled with excessive LRO (greater than
0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles.
Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor
thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in
4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will
develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts).
Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the
cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the
service event for the condition to develop. The customer does not usually make the connection
between the service event and the awareness of the pulsation. The proper usage of torque
wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation
conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly
increases the likelihood of pulsation after wheel service.
The following are examples of pulsation conditions and reimbursement recommendations:
- If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually
got worse, normally the repair would be covered. The customer may tolerate the condition until it
becomes very apparent.
- If a GM dealer performed a prior brake service, consider paying for the repair and then strongly
reinforce proper brake lathe maintenance.
- If the customer had the brake service done outside of a GM dealership, normally GM would not
offer any assistance.
- If a customer indicated they had wheel service, ask who performed the service. Then;
- If a GM dealer performed the service, consider paying for the repair and then strongly reinforce
the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM
products. Each technician needs to use torque sticks properly every time the wheel nuts are
tightened.
- If the customer had the wheel service done outside of a GM dealership, normally GM would not
offer any assistance.
2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another
form of thickness variation, which can cause a
pulsation concern and can be addressed as follows:
- Cosmetic Corrosion:
In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary.
- Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi):
At times more extensive corrosion can cause pulsation due to thickness variation. This usually
happens when the vehicle is parked for long periods of time in humid type conditions and the
braking surface area under the pads corrodes at a different rate compared to the rest of the braking
surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15
moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple
moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure"
below.
- Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi):
In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and
miles can cause the same type of pulsation complaint due to thickness variation. In these cases,
the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against
the darker surface. This darker surface is usually due to build-up, on the rotor material surface,
caused by a combination of corrosion, pad material and heat. To correct this condition, follow the
"Brake Rotor Clean-up Procedure" below.
- Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 +
km (5,000 + miles) :
At times, more extensive corrosion over time and miles can cause pulsation due to thickness
variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by
a combination of corrosion, pad material and heat. When rotor measurements are taken, the low
areas are usually close to the original rotor thickness (new rotor) measurement and the high areas
usually measure more than the original rotor thickness (new rotor) measurement (depending on
mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure"
described below.
Important In some flaking instances, cleaning-up this type of corrosion may require more rotor
material to be removed then desired. Customer consideration should be taken in these situations
and handled on a case by case basis, depending on the amount/percentage of rotor life remaining
and the vehicle's warranty time and miles.
Brake Rotor Clean-Up Procedure
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11236
BRAKE ROTOR CLEAN-UP PROCEDURE
Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and
parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is
clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure"
section in this bulletin.
1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake
pad area of the rotor. Feed the cutting tools into the
rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn.
2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed
during the process, reset zero. Back off a full turn.
3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the
brake pad contact area. Do the same procedure. If
zero is passed during the process, reset zero.
4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the
full rotor surface. Advance both tool cutters to the
zero setting plus just enough to clean up the entire rotor surface.
5. After completing the refinish, sand both sides of the rotor for approximately one minute per side
using a sanding block and 130-150 grit sandpaper
to obtain a non-directional finish.
Important Only remove the necessary amount of material from each side of the rotor and note that
equal amounts of material do not have to be removed from both sides on any brake system using a
floating caliper.
Important In many of these instances, such a minimal amount of material is removed from the rotor
that customer satisfaction is not a concern for future brake services. This procedure is intended to
"Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut",
"refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor
material/life. If the brake lathe equipment being used is not capable of removing minor amounts of
material while holding tolerances, further lathe maintenance, repair, updates or equipment
replacement may be necessary.
Brake Noise
BRAKE NOISE
Some brake noise is normal and differences in loading, type of driving, or driving style can make a
difference in brake wear on the same make and model. Depending on weather conditions, driving
patterns and the local environment, brake noise may become more or less apparent. Verify all
metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and
lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a
"slip-stick" vibration of brake components. While intermittent brake noise may be normal,
performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the
noise persists and is consistently occurring, a brake dampening compound may be applied to the
back of each pad. This allows parts to slide freely and not vibrate when moving relative to each
other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or
equivalent.
The following noises are characteristics of all braking systems and are unavoidable. They may not
indicate improper operation of the brake system.
Squeak/Squeal Noise:
- Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is
applied to the brake pedal.
- Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes
and/or high humidity.
Grinding Noise:
- Common to rear brakes and some front disc brakes during initial stops after the vehicle has been
parked overnight.
- Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few
stops.
Groan Noise:
A groan type noise may be heard when stopping quickly or moving forward slowly from a complete
stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard
braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS
activation.
Key Points - Frequently Asked Questions
KEY POINTS - FREQUENTLY ASKED QUESTIONS
- Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor,
either surface finish or LRO?
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Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11237
A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the
dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no
difference in the cutting/surface finish and LRO are just the same as with a non-floating axle.
- Q: Which lathe is essential for performing brake work, the bench or on-car?
A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These
lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality
brake service.
- Q: What is the expected tip life for an on-car lathe?
A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When
using the Pro-Cut the cutting depth should be set to take all material needed to get below rust
grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381
mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or
"finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last
between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts.
- Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and
on-car brake lathes?
A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant
number of bench and on-car brake lathes. These tests measured critical performance
characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over
many uses. In each test, single pass lathe designs out performed the competitors. Single pass
brake lathes are more productive requiring less time to perform the same procedure.
- Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe?
A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The
debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other
brake concerns and comebacks.
- Q: What information needs to be documented on the Repair Order?
A: Any claim that is submitted using the labor operations in this bulletin, must have the Original
Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For
more information, refer to the "Repair Order Required Documentation" section of this bulletin.
All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited
where the repair does not comply with this procedure.
Brake Warranty
BRAKE WARRANTY
Brake Rotors:
- Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty.
Reference the vehicle's warranty guide for verification.
- Rotors should not be refinished or replaced during normal/routine pad replacement.
- Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type
noises and/or premature lining wear out.
- Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces
can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time
between stops.
- Rotors should not be refinished or replaced for rotor discoloration/hard spots.
- Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a
result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or
corrosion (Lot Rot).
- When rotor refinishing, only remove the necessary amount of material from each side of the rotor
and note that equal amounts of material do not have to be removed from both sides on any brake
system using a floating caliper.
- Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in).
Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should
be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 11238
- It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However,
caution should be exercised, as a variance in surface finish may cause a brake pull condition.
- New rotors should not be refinished before installation. Original equipment rotor surfaces are
ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new
rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the
hub, correct it using one of the following methods:
1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service
Procedure for Hubless Rotors" outlined in this
bulletin.
2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the
procedure outlined in this bulletin.
- Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the
rotor should be replaced.
Important If the Minimum Thickness specification is not visible on the rotor, reference Service
Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor
specifications.
Brake Pads:
Important When determining the warranty coverage (as an example) - if all four front or four rear
brake pads are excessively worn evenly, that would NOT be covered under warranty since this
type of wear is most likely due to driving habits or trailering. However, if the brake pads are
excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration
should be given to cover this under warranty since this type of wear is most likely due to poor
operation of other braking components.
- Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding
owner abuse, excessive trailering, or the situations that would not be considered normal use).
- Installation of new rotors does not require pad replacement. Do not replace pads unless their
condition requires it - excessively worn, damage or contaminated.
Brake Wear:
Several factors impact brake lining wear and should be taken into account when reviewing related
issues:
- heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving /
driver braking characteristics (left foot or two feet)
The following are conditions that may extend brake lining wear:
- light loads / highway driving / conservative driving / level terrain
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Technical Service Bulletins > Page 11239
Brake Rotor/Disc: Specifications
Front Brakes
Brake Rotor Diameter ..........................................................................................................................
........................................ 296.00 mm (11.654 in) Brake Rotor Discard Thickness*
........................................................................................................................................................
27.4 mm (1.079 in) Maximum Allowable Lateral Runout
................................................................................................................................................. 0.06
mm (0.002 in) Maximum Allowable Scoring
...........................................................................................................................................................
1.50 mm (0.059 in)) Maximum Allowable Thickness Variation
...................................................................................................................................... 0.025 mm
(0.001 in)
Rear Brakes
Brake Rotor Diameter ..........................................................................................................................
............................................... 191 mm (7.520 in) Rotor Discard Thickness * .....................................
............................................................................................................................ 18.4 mm (0.724 in)
Maximum Allowable Lateral Runout
................................................................................................................................................. 0.06
mm (0.002 in) Maximum Allowable Scoring
.............................................................................................................................................................
1.50 mm (0.059 in) Maximum Allowable Thickness Variation
....................................................................................................................................... 0.025 mm
(0.001 in)
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet
this specification. After refinishing the rotor, replace any rotor that does not meet the minimum
thickness specifications.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction
Important:
*
Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* The indexing method of correcting assembled LRO is most effective when the LRO specification
is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used
to achieve the best possible match of high spots to low spots between related components. Refer
to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) .
* The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to
correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor
Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral
Runout Correction - Correction Plates) .
* The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) .
If the assembled LRO cannot be corrected using these methods, then other components must be
suspected as causing and/or contributing to the LRO concern.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11242
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Correction Plates
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Tools Required
* J 39544-KIT Complete Torque Socket Set-10 Pieces, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
*
Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor
assembled LRO measurement procedure, to face
upward.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's
instructions, which has a specification closest to the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003
in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm
(0.006 in) correction plate would be used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11243
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during
the brake rotor assembled LRO measurement
procedure.
Important: *
Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO.
* Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in
an attempt to correct brake rotor assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was
positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for
proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and
install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 11. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11244
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing
Brake Rotor Assembled Lateral Runout Correction - Indexing
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
*
Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor
to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a
different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11245
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in
order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11246
Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On
Vehicle Lathe
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Tools Required
J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11247
Brake Rotor/Disc: Testing and Inspection
Brake Rotor Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor
Assembled Lateral Runout Measurement) .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within
specifications. Determine which method to use for the specific vehicle being repaired.
* The indexing method of correcting assembled LRO is most effective when the LRO specification
is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used
to achieve the best possible match of high spots to low spots between related components. Refer
to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled
Lateral Runout Correction - Indexing) .
* The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to
correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor
Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral
Runout Correction - Correction Plates) .
* The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) .
If the assembled LRO cannot be corrected using these methods, then other components must be
suspected as causing and/or contributing to the LRO concern.
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Tools Required
* J 39544-KIT Complete Torque Socket Set-10 Pieces, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11248
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor
assembled LRO measurement procedure, to face
upward.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's
instructions, which has a specification closest to the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003
in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm
(0.006 in) correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during
the brake rotor assembled LRO measurement
procedure.
Important: *
Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO.
* Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in
an attempt to correct brake rotor assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was
positioned to face upward.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11249
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for
proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and
install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 11. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Correction - Indexing
Brake Rotor Assembled Lateral Runout Correction - Indexing
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11250
Thickness Variation Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor
to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a
different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Wheel Removal and Installation .
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still
exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it
was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum
allowable specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11251
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Tools Required
J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
* Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness
variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000
mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from
contacting any rotating components, such as the brake
rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO
measurement procedure and/or the indexing correction
procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are
no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's
instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6.
After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Brake Rotor Thickness
Measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced. After
replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Brake Rotor Assembled
Lateral Runout Measurement) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable
specification, refer to Brake Rotor Assembled Lateral
Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug nuts.
Brake Rotor Assembled Lateral Runout Measurement
Brake Rotor Assembled Lateral Runout Measurement
Tools Required
* J 39544-KIT Torque-Limiting Socket Set, or equivalent
* J 41013 Rotor Resurfacing Kit
* J 42450-A Wheel Hub Resurfacing Kit
* J 45101 Hub and Wheel Runout Gage
* J 45101-100 Conical Brake Rotor Washers
Caution: Refer to Brake Dust Caution .
Important:
* Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can
cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km
(3,000-7,000 mi).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11252
* Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout
(LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation.
Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation
Measurement) .
1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or
contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces.
Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which
could lead to brake pulsation.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no
foreign particles, corrosion, rust, or debris
remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these
conditions, perform the following steps:
1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (See: Service
and Repair/Removal and Replacement/Front
Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and
Repair/Removal and Replacement/Rear Brake Rotor Replacement) .
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating
surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol,
or an equivalent approved brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1),
and one lug nut (2) onto the upper-most wheel
stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly
by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a
star-pattern to specification, in order to properly secure the rotor. Refer to Tire and
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11253
Wheel Removal and Installation .
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9.
If the brake rotor meets the following criteria, proceed to step 10.
* The rotor is within specifications and is being REUSED.
* The rotor has NOT been refinished.
* The rotor does NOT exhibit thickness variation exceeding the maximum allowable level.
10. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
13. If the brake rotor assembled LRO is within specifications, proceed to step 18.
If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true
parallelism. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures) . After
refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator
button so it contacts the brake rotor friction
surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
15. Measure and record the assembled LRO of the brake rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to
zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the
high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification:
* Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
* Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled
Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper
and depress the brake pedal several times to secure
the rotor in place before removing the J 45101-100 and the lug nuts.
Brake Rotor Surface and Wear Inspection
Brake Rotor Surface and Wear Inspection
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11254
Caution: Refer to Brake Dust Caution .
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface
Conditions:
* Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface
rust and/or pitting must be removed by refinishing the rotor.
* Cracks and/or heat spots
* Excessive blueing discoloration
4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions,
the rotor requires refinishing or replacement.
5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch,
measure and record the scoring depth of any grooves
present on the rotor friction surfaces.
6. Compare the groove scoring depth recorded to the following specification:
Brake rotor maximum allowable scoring: 1.50 mm (0.059 in)
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is
present, the rotor requires refinishing or
replacement.
Brake Rotor Thickness Measurement
Brake Rotor Thickness Measurement Caution: Refer to Brake Dust Caution .
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner. 3. Using a micrometer calibrated in thousanths-of-a-milimeter, or
ten-thousanths-of-an-inch, measure and record the lowest thickness of the brake
rotor at 4 or more points, equally spaced around the rotor. Ensure that the measurements are only
taken within the friction surfaces and that the micrometer is positioned the same distance from the
outside edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Compare the lowest thickness measurement recorded to the following specifications:
Brake rotor discard thickness: 27.4 mm (1.079 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Testing and Inspection > Brake Rotor Assembled Lateral Runout Correction > Page 11255
Brake rotor discard thickness: 18.4 mm (0.724 in)
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable
thickness after refinishing specification, the rotor may be
able to be refinished, depending upon surface and wear conditions which may be present.
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable
thickness after refinishing specification, the rotor may
not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness
specification, the rotor requires replacement.
Brake Rotor Thickness Variation Measurement
Brake Rotor Thickness Variation Measurement Caution: Refer to Brake Dust Caution .
Important: Any disc brake rotor that exhibits thickness variation exceeding the maximum
acceptable level must be refinished or replaced. Thickness variation exceeding the maximum
acceptable level can cause brake pulsation.
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the
caliper with the brake pads. Refer to Front Disc Brake
Pads Replacement (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement)
and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Rear Disc Brake
Pads Replacement) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch,
measure and record the thickness of the brake rotor at
four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken
within the friction surfaces and that the micrometer is positioned the same distance from the outer
edge of the rotor, about 13 mm (0.5 in), for each measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to
obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the
following specification:
Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in)
Important: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of
the rotor must be measured to ensure optimum performance of the disc brakes.
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires
refinishing or replacement.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures
Brake Rotor/Disc: Procedures
Brake Rotor Refinishing
Tools Required
* J 41013 Rotor Resurfacing Kit
* J 42450-A Wheel Hub Resurfacing Kit
Caution: Refer to Brake Dust Caution .
Important:
* The disc brake rotors do not require refinishing as part of routine brake system service. New disc
brake rotors do not require refinishing.
Do not refinish disc brake rotors in an attempt to correct the following conditions:
- Brake system noise - squeal, growl, groan
- Uneven and/or premature disc brake pad wear
- Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface
- Scoring of the disc brake rotor friction surface less than the maximum allowable specification
* Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow
the rotor to be refinished and remain above the minimum allowable thickness after refinish
specification. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if
one or more of the following conditions exist:
- Thickness variation in excess of the maximum allowable specification
- Excessive corrosion/rust and/or pitting
- Cracks and/or heat spots
- Excessive blueing discoloration
- Scoring of the disc brake rotor surface in excess of the maximum allowable specification
* Disc brake rotors may need to be refinished as part of the process for correcting brake rotor
assembled lateral runout (LRO) that exceeds the maximum allowable specification.
Important: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling.
This setup requires less cutting pressure, which will result in less vibration, and a better surface
finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following
instructions.
Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust
or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this
may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to
brake pulsation.
1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. 2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating
surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle
flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the
brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all
mounting attachments and adapters are
clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe
running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7.
Observe the witness mark on the brake rotor. If the witness mark extends approximately
three-quarters or more of the way around the brake rotor
friction surface on each side, the brake rotor is properly mounted to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor,
re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the
brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement (See: Testing and Inspection/Brake
Rotor Thickness Measurement) .
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish
specification, the brake rotor must be replaced.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 11258
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired
non-directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish. 2. Using moderate pressure, apply the non-directional finish:
* If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum
oxide sandpaper.
* If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding
block and 150-grit aluminum oxide sandpaper.
3. After applying a non-directional finish, clean each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake
rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral
Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Measurement) .
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to
within specifications. Refer to Brake Rotor Assembled
Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout
Correction) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 11259
Brake Rotor/Disc: Removal and Replacement
Brake Pad and Rotor Burnishing
Brake Pad and Rotor Burnishing
Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.
Caution: Refer to Brake Dust Caution .
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking
surfaces are properly prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or
replaced, and/or whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph).
Important: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the
brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow
sufficient cooling periods between stops in order to properly
burnish the brake pads and rotors.
Front Brake Rotor Replacement
Front Brake Rotor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 11260
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 11261
Rear Brake Rotor Replacement
Rear Brake Rotor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Service and Repair > Procedures > Page 11262
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure
Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure
Antilock Brake System Automated Bleed Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important: Before performing the antilock brake system (ABS) Automated Bleed Procedure, first
perform a manual or pressure bleed of the base brake system. Refer to Hydraulic Brake System
Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: ) . The automated
bleed procedure is recommended when one of the following conditions exist:
* Base brake system bleeding does not achieve the desired pedal height or feel
* Extreme loss of brake fluid has occurred
* Air ingestion is suspected in the secondary circuits of the brake modulator assembly
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in
these circuits to flow out toward the brake corners.
Automated Bleed Procedure
Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing
the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be
given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid
causing damage to components and painted surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove all 4 tire and
wheel assemblies. Refer to Tire and Wheel Removal and Installation . 3. Inspect the brake system
for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and
Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as needed.
4. Lower the vehicle. 5. Inspect the battery state of charge. Refer to Battery Inspection/Test . 6.
Install a scan tool. 7. Turn the ignition ON, with the engine OFF. 8. With the scan tool, establish
communications with the ABS system. Select Special Functions. Select Automated Bleed from the
Special Functions
menu.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
10. Following the directions given on the scan tool, pressure bleed the base brake system. Refer to
Hydraulic Brake System Bleeding (Manual) (See:
)Hydraulic Brake System Bleeding (Pressure) (See: ) .
11. Follow the scan tool directions until the desired brake pedal height is achieved. 12. If the bleed
procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed
procedure:
* If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle , and diagnose the
appropriate DTC.
* If the brake pedal feels spongy, perform the conventional brake bleed procedure again. Refer to
Hydraulic Brake System Bleeding (Manual) ( See: )Hydraulic Brake System Bleeding (Pressure)
(See: ) .
13. When the desired pedal height is achieved, press the brake pedal to inspect for firmness. 14.
Lower the vehicle. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation . 17. Inspect the brake fluid level. Refer to Master
Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master
Cylinder Reservoir Filling) .
18. Road test the vehicle while inspecting that the pedal remains high and firm.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 11268
Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding
Manual
Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the
brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Ensure the brake master cylinder reservoir remains at least half-full during this bleeding
procedure. Add fluid as needed to maintain the proper
level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6.
Install a transparent hose over the end of the bleeder valve. 7. Have an assistant slowly depress
the brake pedal fully and maintain steady pressure on the pedal. 8. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant
slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic
circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all
air has been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
12. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 13. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 15. With
the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 17. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
18. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 19. If the
brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure,
perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 11269
20. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
21. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Pressure
Hydraulic Brake System Bleeding (Pressure)
Tools Required
* J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent
* J 44894-A Brake Pressure Bleeder Adapter
Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the
ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster
power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, or
if you have disconnected the brake pipes from the proportioning valve assembly or the brake
modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic
component:
1. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on
and around the cap prior to removal. 2. With the brake pipes installed securely to the master
cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate
one of the brake pipes from the port of the component. For the proportioning valve assembly or the
brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid
feed pipes from the master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 4.
Reconnect the brake pipe to the component and tighten securely. 5. Have an assistant slowly
depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same
brake pipe to purge air from the open port of the component. 7. Tighten the brake pipe, then have
the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all
air is purged from the same port of the component. 9. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or brake modulator assembly, and after all air has
been purged from the first port of the component that was bled, loosen and separate the next brake
pipe from the component, then repeat steps 3.3-3.8 until each of the ports on the component has
been bled.
10. After completing the final component port bleeding procedure, ensure that each of the brake
pipe-to-component fittings is properly tightened.
4. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Connect the J 29532 ,
or equivalent, to the J 44894-A . 7. Charge the J 29532 , or equivalent, air tank to 175-205 kPa
(25-30 psi). 8. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to
enter the brake system. 9. Wait approximately 30 seconds, then inspect the entire hydraulic brake
system in order to ensure that there are no existing external brake fluid
leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
10. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
11. Install a transparent hose over the end of the bleeder valve. 12. Loosen the bleeder valve to
purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the
bleeder, then
tighten the bleeder valve.
13. With the right rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the right rear hydraulic circuit,
install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 15. With
the left front wheel hydraulic circuit bleeder valve tightened securely, and after all air has been
purged from the left front hydraulic circuit,
install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 11270
17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, and after all air has
been purged from the left rear hydraulic circuit,
install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. After
completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves is properly
tightened.
20. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent,
from the J 44894-A . 21. Remove the J 44894-A from the brake master cylinder reservoir. 22.
Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 23. If the brake
pedal feels spongy perform the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection
(See: Testing and Inspection/Component Tests
and General Diagnostics/Brake System External Leak Inspection) .
2. If equipped with antilock brakes, using a scan tool, perform the antilock brake system automated
bleeding procedure to remove any air that
may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake
System Automated Bleed Procedure (See: ) .
24. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp
remains illuminated.
Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
25. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes
(See: Testing and Inspection/Symptom Related
Diagnostic Procedures/Symptoms - Hydraulic Brakes) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 11271
Brake Bleeding: Service and Repair Hydraulic Brake System Flushing
Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
* Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance-Oil-based substance
- Layered appearance-Silicone-based substance
* Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
- Cloudy appearance-Moisture
- Dark appearance/suspended particles in fluid-Dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid
contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated
by fluid separation and/or a swollen master
cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the
procedures indicated:
* Master Cylinder Reservoir Replacement (See: Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Reservoir Replacement)
* Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Front Brake Caliper
Replacement)
* Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Rear Brake Caliper
Replacement)
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake
pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed
and install them to the vehicle. Each component contains internal rubber
seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic
system. Refer to the procedures indicated:
* Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Master
Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement) .
Replace the brake master cylinder reservoir cap diaphragm.
* Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and
Replacement/Master Cylinder Replacement)
* Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose
Replacement)
* Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose
Replacement)
* Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Front Brake Caliper
Replacement)
* Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Rear Brake Caliper
Replacement)
* Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement)
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may
have allowed the moisture or particles to enter the hydraulic system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Antilock Brake System Automated Bleed Procedure > Page 11272
5. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct
brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic
Brake System Bleeding (Pressure) (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information
Brake Caliper: Technician Safety Information
Caliper Piston Removing Caution
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it
when applying compressed air. The piston(s) can fly out with force and could result in serious
bodily injury.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Technician Safety Information > Page 11277
Brake Caliper: Vehicle Damage Warnings
Brake Caliper Notice
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service Precautions > Page 11278
Brake Caliper: Testing and Inspection
Brake Caliper Inspection
Caution: Refer to Brake Dust Caution . Caution: Refer to Brake Fluid Irritant Caution .
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these
conditions are present, the brake caliper requires
replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper
seating in the caliper body. If any of these
conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake
pads. If there is any evidence of brake fluid
leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper piston, or pistons, into the caliper bore, or
bores:
The movement of a caliper piston into a caliper bore should be smooth and even. If a caliper piston
is frozen or difficult to bottom, the caliper requires overhaul or replacement.
* For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
* For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the pistons evenly into the bores.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement
Brake Caliper: Service and Repair Front Brake Caliper Replacement
Front Brake Caliper Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11281
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11282
Brake Caliper: Service and Repair Rear Brake Caliper Replacement
Rear Brake Caliper Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11283
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11284
Brake Caliper: Service and Repair Front Brake Caliper Bracket Replacement
Front Brake Caliper Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11285
Brake Caliper: Service and Repair Rear Brake Caliper Bracket Replacement
Rear Brake Caliper Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front Brake Caliper Replacement > Page 11286
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
HYDRAULIC BRAKE SYSTEM
Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 11293
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 11294
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Disconnect the brake fluid level indicator switch electrical
connector.
3. While simultaneously depressing the retaining tabs on the opposite side of the switch electrical
connection, carefully pull the switch from the
master cylinder reservoir.
4. Remove the low brake fluid level sensor.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch
> Component Information > Locations > Page 11295
1. While noting the proper orientation, install the brake fluid level indicator switch to the master
cylinder. 2. Press the brake fluid level indicator switch firmly into the master cylinder reservoir,
ensuring that the retaining tabs are fully engaged.
3. Connect the brake fluid level indicator switch electrical connector. 4. Install the underhood
electrical center bracket. Refer to Underhood Electrical Center or Junction Block Bracket
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement
Brake Hose/Line: Service and Repair Brake Pipe Replacement
Brake Pipe Replacement
Tools Required
J 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution .
Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any
other pipe is not recommended and may cause brake system failure. Carefully route and retain
replacement brake pipes. Always use the correct fasteners and the original location for
replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to
the brake pipes and cause brake system failure.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Important: When servicing the brake pipes, note the following:
*
If sectioning the brake pipe, use replacement pipe of the same type and outside diameter.
* Use fittings of the appropriate size and type.
* Only create flares of the same type or design as originally equipped on the vehicle.
1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be
replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe,
if necessary.
* Allow adequate clearance in order to maneuver the J 45405 .
* Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5.
Add to the measurement taken the appropriate additional length required for each flare to be
created.
* 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
* 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe
* 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe
Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the
pipe length.
6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the
measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate
size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake
pipe size.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11300
9. Strip the nylon coating from the brake pipe end to be flared, if necessary.
* Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the tool
rollers.
- 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
* Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
* While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the
metal surface of the brake pipe.
* Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains
against the tool roller ledges.
* After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface
is exposed.
* Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose
remnants of the nylon coating have been removed from the brake pipe.
* Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
- 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
- 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J
45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe
and the J 45405 of lubricant, contaminants, and debris.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11301
13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install
the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the
counterbores of both dies facing the forming ram.
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the
enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11302
20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic
fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it
bottoms against the die cage.
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever
of the J 45405 until the forming mandrel bottoms
against the clamping dies.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract.
25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve
clockwise to the closed position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11303
27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the
finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the
finishing cone bottoms
against the dies.
29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe.
31. If necessary, lightly tap the dies until the die halves separate.
32. Inspect the brake pipe flare for correct shape and diameter (a).
* 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
* 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe
* 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe
33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or
vibrating components.
34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If
previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and
Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11304
Brake Hose/Line: Service and Repair Front Brake Hose Replacement
Front Brake Hose Replacement Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation . 3. Release the wheel speed
sensor harness retaining clips (1) and release the harness.
4. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting. 5. Using a
backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose. Cap or
plug the brake pipe fitting end and the
brake hose end to prevent fluid loss and contamination.
6. Release the retaining clip from the brake hose mounting bracket and the brake hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11305
7. Remove the brake hose fitting bolt from the brake caliper. 8. Remove the brake hose bracket
retaining bolt. 9. Remove the brake hose from the brake caliper.
10. Remove and discard the copper brake hose gaskets. These gaskets may be stuck to the brake
caliper and/or the brake hose end. 11. Cap or plug the opening in the brake caliper and the brake
hose to prevent fluid loss and contamination.
Installation Procedure
1. Remove the caps or plugs from the opening in the brake caliper and the brake hose.
Important: Install NEW copper brake hose gaskets.
2. Assemble the NEW copper brake hose gaskets, and the brake hose bolt, to the brake hose.
Notice: Refer to Fastener Notice .
3. Install the brake hose fitting bolt to the brake caliper.
Tighten the bolt to 52 N.m (38 lb ft).
4. Install the front brake hose bracket retaining bolt.
Tighten the bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11306
5. Install the wheel speed sensor harness and secure the retaining clips (1).
6. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 7. Using a
backup wrench on the hose fitting, connect the brake pipe fitting at the front brake hose.
Tighten the fitting to 18 N.m (13 lb ft).
8. Install the brake hose retaining clip to the brake hose and the brake hose mounting bracket. 9.
Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
10. Ensure that the hose does not make contact with any part of the suspension. Check the hose in
extreme right and extreme left turn conditions. If the
hose makes contact, remove the hose and correct the condition.
11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See:
Brake Bleeding/Service and Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
12. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11307
Brake Hose/Line: Service and Repair Rear Brake Hose Replacement
Rear Brake Hose Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Pipe Replacement > Page 11308
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Replacement
Brake Pressure Modulator Valve Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page
11313
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Replacement > Page
11314
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve
Bracket Replacement
Brake Pressure Modulator Valve Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures
Brake Master Cylinder: Procedures
Master Cylinder Bench Bleeding
Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the
primary piston is accessible. 2. Remove the cap from the hose nipple on the master cylinder
reservoir. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat
required and also provide for hose attachment. 4. Install transparent hoses to the fittings, then
route the hoses into the master cylinder reservoir. 5. Ensure that the ends of the transparent hoses
running into the reservoir are fully submerged in the brake fluid. 6. Using a smooth, round-ended
tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in),
several times.
Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary
pistons, the effort required to depress the primary piston will increase and the amount of travel will
decrease.
7. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles. 8. Remove the transparent hoses from the reservoir. 9. Install the cap to
the hose nipple on the reservoir, to prevent fluid loss and contamination.
10. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master
cylinder with a clean shop cloth to prevent brake
fluid spills.
11. Remove the master cylinder from the vise.
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Visually inspect the brake fluid level through the brake master cylinder auxiliary reservoir. 2. If
the brake fluid level is at or below the half-full point during routine fluid checks, the brake system
should be inspected for wear and possible
brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or
brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the
maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not
recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder
auxiliary reservoir, clean the outside of the reservoir on and around the reservoir cap prior to
removing the cap and diaphragm.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 11319
Brake Master Cylinder: Removal and Replacement
Master Cylinder Reservoir Replacement
Master Cylinder Reservoir Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: When adding fluid to the brake master cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid
other than the recommended type of brake fluid may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Remove the brake fluid from the reservoir. Discard the
fluid into an approved container. 3. Disconnect the brake fluid level sensor electrical connector.
4. Remove the brake fluid level indicator switch. Refer to Brake Fluid Level Indicator Switch
Replacement (See: Brake Fluid Level
Sensor/Switch/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 11320
5. Remove the master cylinder reservoir attachment pins and discard the pins. 6. Release the
reservoir from the master cylinder by carefully pulling reservoir straight up. 7. Remove the reservoir
seals from the master cylinder body.
Installation Procedure
1. Install the reservoir seals to the master cylinder body. 2. Install the reservoir to the master
cylinder body by pushing the reservoir bayonets straight down into the seals in the master cylinder
body. 3. Install NEW reservoir attachment pins. Ensure that the attachment pins are fully and firmly
seated.
4. Install the brake fluid level indicator switch. Refer to Brake Fluid Level Indicator Switch
Replacement (See: Brake Fluid Level
Sensor/Switch/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 11321
5. Connect the brake fluid level sensor electrical connector. 6. Install the underhood electrical
center. Refer to Underhood Electrical Center or Junction Block Bracket Replacement . 7. Fill the
master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See: Procedures/Master
Cylinder Reservoir Filling) . 8. Bleed the brake system. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System
Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
Master Cylinder Replacement
Master Cylinder Replacement
Removal Procedure Caution: Refer to Brake Fluid Irritant Caution .
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice .
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Disconnect the electrical connector from the brake fluid
level indicator switch.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 11322
3. Disconnect the brake pipes from the master cylinder.
Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent
brake fluid loss and contamination.
4. Plug the open brake pipe ends.
5. Remove master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7.
Drain the master cylinder reservoir of all brake fluid.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Procedures > Page 11323
1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (See:
Procedures/Master Cylinder Bench Bleeding) . 2. Install the master cylinder to the brake booster.
Notice: Refer to Fastener Notice .
3. Install the master cylinder mounting nuts.
Tighten the master cylinder mounting nuts to 25 N.m (18 lb ft).
4. Remove the plugs from the brake pipes. 5. Connect the brake pipes to the master cylinder.
Tighten the brake pipe fittings at the master cylinder to 18 N.m (13 lb ft).
6. Connect the electrical connector to the brake fluid level indicator switch. 7. Install the underhood
electrical center bracket. Refer to Underhood Electrical Center or Junction Block Bracket
Replacement . 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake
System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator >
Component Information > Service and Repair
Parking Brake Actuator: Service and Repair
Parking Brake Actuator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement
Parking Brake Cable: Service and Repair Parking Brake Front Cable Replacement
Parking Brake Front Cable Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement .
3. With park brake lever in the released position, using ONLY hand tools, remove the park brake
cable adjusting nut and washer. 4. Release the rear park brake cable ends from the cable equalizer
on the front cable. 5. Remove the front park brake cable from the park brake lever by pulling the
cable rearward.
Installation Procedure
1. Install the front park brake cable to the park brake lever. 2. Install the rear cable ends to the
cable equalizer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11332
3. Using ONLY hand tools, install the washer and NEW adjusting nut (1) to the front park brake
cable. 4. Adjust the park brake cable tension. Refer to Park Brake Adjustment (See: Adjustments) .
5. Install the front floor console. Refer to Console Replacement . 6. Enable the SIR system. Refer
to SIR Disabling and Enabling .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11333
Parking Brake Cable: Service and Repair Parking Brake Rear Cable Replacement
Parking Brake Rear Cable Replacement
Removal Procedure
Tools Required
J 37043 Park Brake Cable Release Tool
1. Remove the front floor console. Refer to Console Replacement . 2. Ensure the park brake lever
is in the fully released position.
3. Release the tension from the park brake cable system at the front cable adjusting nut (1).
Using only hand tools, loosen the adjusting nut (1) completely to the end of the front cable threaded
rod.
4. Remove the rear carpet retainers. Refer to Rear Carpet Retainer Replacement . 5. Position the
carpet forward in order to access the rear park brake cables and body pass-through grommets. 6.
With the park brake lever (1) in the released position, release the appropriate rear park brake cable
(2) from the cable equalizer. 7. Release the rear cable fitting from the park brake lever bracket and
remove the cable from the lever assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11334
8. Fold back the park brake cable routing tabs on the vehicle interior floor. 9. Release the rear park
brake cable body pass-through grommet.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 11. Remove the rear
tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 12. Remove the bolt
(1) from the park brake cable-to-underbody retainer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11335
13. Remove the bolt (1) from the park brake cable retainer at the lower suspension trailing arm. 14.
Remove the cable (2) from the opening in the vehicle underbody.
15. Slide the inner cable (1) forward and remove from the actuator. 16. Slide the spring (2) forward
17. Using the J 37043 , remove the park brake cable from the mounting bracket
Installation Procedure
Important: After installing the park brake cable in the mounting bracket, ensure that the locking tabs
on the cable are open and seated correctly against the mounting bracket.
1. Install the park brake cable in the mounting bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11336
2. Slide the inner cable forward (1) and install on the park brake actuator . 3. Position the spring (2)
against the mounting bracket. 4. Install the rear tire and wheel assembly. Refer to Tire and Wheel
Removal and Installation .
5. Insert the cable (2) through the opening in the vehicle underbody. 6. Install the park brake cable
retaining bracket to the rear suspension lower trailing arm.
Notice: Refer to Fastener Notice .
7. Install the bolt (1) to the park brake cable retainer and lower trailing arm.
Tighten the bolt and nut to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11337
8. Install and secure park brake cable pass-through grommet to the opening in the vehicle
underbody. 9. Install the park brake cable (2) to the underbody retainer.
10. Install the bolt to the park brake cable retainer and the vehicle underbody (3).
Tighten the bolt to 25 N.m (18 lb ft).
11. Lower the vehicle.
12. Secure the cable fitting to the park brake lever bracket. Attempt to pull the park brake cable free
of the lever bracket, to ensure that the retaining
tabs on the fitting are properly secured.
13. Install the cable end (2) to the cable equalizer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Front Cable Replacement > Page 11338
14. Position park brake cable to routing tabs on vehicle interior floor. 15. Secure park brake cable
to floor by folding routing tabs over park brake cable. 16. Reposition the carpet to the installed
position. 17. Install the rear carpet retainers. Refer to Rear Carpet Retainer Replacement . 18.
Adjust the park brake cable tension. Refer to Park Brake Adjustment (See: Adjustments) . 19.
Install the front floor console. Refer to Console Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair
Parking Brake Lever: Service and Repair
Park Brake Lever Assembly Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Ensure that the park brake
lever is in the fully released position.
4. Release the tension from the park brake cable system at the front cable adjusting nut (1). 5.
Using ONLY hand tools, loosen the adjusting nut (1) completely to the end of the front cable
threaded rod.
6. Disconnect the electrical connector from the park brake warning lamp switch.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 11342
7. With the park brake lever (1) in the released position, release the rear park brake cable (2) ends
from the cable equalizer. 8. Release the rear cable fittings from the park brake lever bracket.
9. Remove the park brake lever mounting nuts.
10. Remove the park brake lever assembly from the vehicle.
Installation Procedure
1. Install the park brake lever assembly to the vehicle.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Service and Repair > Page 11343
2. Install the park brake lever assembly mounting nuts.
Tighten the nuts to 25 N.m (18 lb ft).
3. Secure the rear cable fittings to the park brake lever bracket. Attempt to pull the park brake
cables free of the lever bracket, to ensure that the
retaining tabs on the fittings are properly secured.
4. Install the cable ends to the cable equalizer.
5. Connect the electrical connector to the park brake warning lamp switch. 6. Adjust the park brake
cable tension. Refer to Park Brake Adjustment (See: Adjustments) . 7. Install the front floor
console. Refer to Console Replacement . 8. Enable the SIR system. Refer to SIR Disabling and
Enabling .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations
Parking Brake Release Switch: Locations
Passenger Compartment/Roof Component Views
Park Brake Assembly Components
1 - Park Brake Switch 2 - Park Brake Handle 3 - Floor Panel
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Locations > Page 11347
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair
Parking Brake Shoe: Service and Repair
Parking Brake Shoe Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 11351
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair
Vacuum Brake Booster: Service and Repair
Power Vacuum Brake Booster Replacement
Removal Procedure
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Disconnect the coolant surge hose from the surge tank
and position aside. 3. Remove the master cylinder mounting nuts. Do not disconnect the brake
pipes from the master cylinder. 4. Carefully pull the master cylinder away from the vacuum booster
and position aside. 5. Disconnect the vacuum booster check valve and hose assembly from the
booster. Refer to Vacuum Brake Booster Check Valve and/or Hose
Replacement (See: Vacuum Brake Booster Check Valve/Service and Repair) .
6. Remove the brake pressure modulator valve assembly. Refer to Brake Pressure Modulator
Valve Replacement (See: Antilock Brakes / Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement) .
7. Remove the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve
Bracket Replacement (See: Antilock Brakes /
Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Bracket Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 11359
8. Remove the brake booster push rod-to-brake pedal retaining clip. 9. Remove the foam washer
from the brake pedal assembly.
10. Remove the brake booster mounting nuts.
Important: Ensure that the foam insulator on the mounting surface of the brake booster withdraws
with the booster.
11. Disengage the brake booster from the front of dash and the brake pedal bracket. Maneuver the
booster toward the center of the vehicle in order to
ease removal.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 11360
1. Install the foam insulator the vacuum brake booster. 2. Install the brake booster to the vehicle. 3.
Install, but do not tighten, the booster mounting nuts. 4. Lightly lubricate the booster push rod pivot
pin on the brake pedal with silicone lubricant. 5. Install the booster push rod to the pivot pin on the
brake pedal. 6. Install the foam washer to the pivot pin. 7. Install the brake booster push rod
retaining clip.
8. Fully seat the brake booster to the front of dash and the brake pedal assembly.
Notice: Refer to Fastener Notice .
9. Tighten the vacuum brake booster mounting nuts.
Tighten the nuts to 25 N.m (18 lb ft).
10. Install the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve
Bracket Replacement (See: Antilock Brakes /
Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake
Pressure Modulator Valve Bracket Replacement) .
11. Install the brake pressure modulator valve assembly. Refer to Brake Pressure Modulator Valve
Replacement (See: Antilock Brakes / Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure
Modulator Valve Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Page 11361
12. Install the vacuum booster check valve and hose assembly to the booster. 13. Install the
master cylinder to the booster. Refer to Master Cylinder Replacement (See: Hydraulic
System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Master Cylinder Replacement) .
14. Install the coolant surge hose and clamp to the surge tank. 15. Install the underhood electrical
center bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement . 16.
If necessary, bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding
(Manual) (See: Brake Bleeding/Service and Repair
)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Service and Repair
Vacuum Brake Booster Check Valve: Service and Repair
Vacuum Brake Booster Check Valve and/or Hose Replacement
Removal Procedure
1. Release the retaining clamp (1) and remove the vacuum hose (2) from the vacuum port on the
engine.
2. Remove the check valve and hose from the brake booster by gently turning the check valve right
then left while pulling straight out from the
grommet.
3. Remove the vacuum hose from the check valve.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Service and Repair > Page 11365
1. Install the vacuum hose to the check valve. 2. Install the brake booster check valve and hose
assembly to the booster.
3. Install the vacuum hose (2) to the engine vacuum port. 4. Install the vacuum hose clamp (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 >
Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 >
Campaign - ESC/Steering Module Reprogramming > Page 11375
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 >
Campaign - ESC/Steering Module Reprogramming > Page 11376
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 >
Campaign - ESC/Steering Module Reprogramming > Page 11377
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 >
Campaign - ESC/Steering Module Reprogramming > Page 11378
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 11384
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 11390
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
11395
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
11396
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
11397
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
11398
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Electronic Brake Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 11404
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11410
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11411
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11412
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Electronic Brake Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 11413
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11414
Electronic Brake Control Module: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11415
Electronic Brake Control Module: Diagrams
Component Connector End Views
Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11416
Electronic Brake Control Module (EBCM) (Pin 1 To 35)
Electronic Brake Control Module (EBCM) (Pin 36 To 47)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11417
Electronic Brake Control Module: Service and Repair
Electronic Brake Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control >
Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 11418
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Cowl Components
1 - Brake Fluid Level Switch 2 - Left Front Strut Tower 3 - Electronic Brake Control Module (EBCM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 11423
Brake Fluid Level Sensor/Switch: Diagrams
Component Connector End Views
Brake Fluid Level Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 11424
Brake Fluid Level Sensor/Switch: Service and Repair
Brake Fluid Level Indicator Switch Replacement
Removal Procedure
1. Remove the underhood electrical center bracket. Refer to Underhood Electrical Center or
Junction Block Bracket Replacement . 2. Disconnect the brake fluid level indicator switch electrical
connector.
3. While simultaneously depressing the retaining tabs on the opposite side of the switch electrical
connection, carefully pull the switch from the
master cylinder reservoir.
4. Remove the low brake fluid level sensor.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 11425
1. While noting the proper orientation, install the brake fluid level indicator switch to the master
cylinder. 2. Press the brake fluid level indicator switch firmly into the master cylinder reservoir,
ensuring that the retaining tabs are fully engaged.
3. Connect the brake fluid level indicator switch electrical connector. 4. Install the underhood
electrical center bracket. Refer to Underhood Electrical Center or Junction Block Bracket
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations
Parking Brake Release Switch: Locations
Passenger Compartment/Roof Component Views
Park Brake Assembly Components
1 - Park Brake Switch 2 - Park Brake Handle 3 - Floor Panel
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Release Switch > Component Information > Locations > Page 11429
Parking Brake Release Switch: Diagrams
Component Connector End Views - Continued
Park Brake Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Parking Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Steering Angle Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Angle Sensor Centering
The steering angle sensor does not require centering often. Centering of the steering angle sensor
might be required after certain service procedures are performed. Some of these procedures are
as follows:
* Steering gear replacement
* Steering column replacement
* Steering angle sensor replacement
* Intermediate shaft replacement
* Antilock brake system (ABS) controller replacement
* Collision or other physical damage
The steering angle sensor centering procedure can be preformed with a scan tool in the automated
center procedure by the following:
1. Using the steering wheel, align the front wheels forward. 2. Set the transmission in the PARK
position. 3. Install the scan tool to the data link connector (DLC). 4. Turn the ignition switch ON,
with the engine OFF. 5. Select Chassis/EBCM control system vehicle stability enhancement
system (VSES), special function test, and Steering Pos. Sensor Calibration. 6. Follow the scan tool
directions to complete the automated centering procedure this should include turning the steering
wheel left 5 degrees and
right 5 degrees and then straight forward.
7. Clear any DTCs that may be set. Perform the Diagnostic System Check to verify no current
DTCs. Refer to Diagnostic System Check - Vehicle . 8. Centering of the steering angle sensor is
complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Locations
Traction Control Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Locations > Page 11439
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Locations > Page 11440
Traction Control Switch: Diagrams
Component Connector End Views - Continued
Traction Control Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Locations > Page 11441
Traction Control Switch: Service and Repair
Electronic Traction Control Switch Replacement
Removal Procedure
1. Remove the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
2. Carefully release the retaining tabs and remove the traction control switch from the trim bezel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Traction Control Switch > Component Information > Locations > Page 11442
1. Install the traction control switch to the trim bezel. Ensure that the retaining tabs are fully
engaged.
2. Install the instrument panel (I/P) trim bezel. Refer to Instrument Panel Accessory Bezel
Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
Wheels/Vehicle Underbody Component Views
Left Front Suspension Components
1 - X103 Left Shown, X104 Right Similar 2 - Wheel Speed Sensor (WSS) - Left Front, Right Front
Similar
Rear Axle Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 11446
1 - Rear Cradle 2 - Wheel Speed Sensor (WSS) - Left Rear 3 - Wheel Speed Sensor (WSS) - Right
Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 11447
Wheel Speed Sensor: Diagrams
Component Connector End Views - Continued
Wheel Speed Sensor - Left Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 11448
Wheel Speed Sensor - Right Front
Reverse Lockout Solenoid
Wheel Speed Sensor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Locations > Page 11449
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement
Front Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page
11452
Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 11456
Yaw Rate Sensor: Diagrams
Component Connector End Views - Continued
Yaw Rate and Lateral Acceleration Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw
Rate Sensor > Component Information > Locations > Page 11457
Yaw Rate Sensor: Service and Repair
Vehicle Yaw Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 11463
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 11464
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current
Sensor > Component Information > Locations > Page 11465
1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11482
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11483
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11484
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11485
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11486
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Procedures > Page 11487
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair
Negative: Service and Repair
Battery Negative Cable Replacement (LNJ)
Removal Procedure
Important:
* Always use replacement cables that are of the same type, diameter and length of the cables that
you are replacing.
* Always route the replacement cable the same way as the original cable.
1. Remove the battery box. 2. Disconnect the positive and negative battery cable clip (3) from the
battery tray support bracket. 3. Disconnect the positive and negative battery cable clip on the side
of the battery tray support bracket.
4. Disconnect the negative battery cable electrical connector (7) from the body wiring harness
electrical connector (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 11497
5. Disconnect the body wiring harness electrical connector (4) from the battery current sensor (5).
6. Remove the negative battery cable ground terminal nut from the wheelhouse stud. 7. Remove
the negative battery cable ground terminal from the wheelhouse stud.
8. Remove the negative battery cable ground terminal nut (2) from the transaxle stud. 9. Remove
the engine wiring harness ground lead (1) from the stud.
10. Remove the negative battery cable (3) lead from the stud.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 11498
11. Remove the battery cable retainer (4) from the transaxle selector cable bracket. 12. Cut the
tape and remove the negative battery cable from the wiring loom.
Installation Procedure
1. Install the negative battery cable to the wiring loom and re-tape the loom. 2. Install the battery
cable retainer (4) to the transaxle selector cable bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 11499
3. Install the negative battery cable (3) lead to the stud. 4. Install the engine wiring harness ground
lead (1) to the stud.
Notice: Refer to Fastener Notice.
5. Install the negative battery cable ground terminal nut (2) to the transaxle stud.
Tighten the nut to 45 N.m (33 lb ft).
6. Install the negative battery cable ground terminal to the wheelhouse stud. 7. Install the negative
battery cable ground terminal nut to the wheelhouse stud.
Tighten the nut to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System
Information > Service and Repair > Page 11500
8. Connect the body wiring harness electrical connector (4) to the battery current sensor (5). 9.
Connect the negative battery cable electrical connector (7) to the body wiring harness electrical
connector (2).
10. Connect the positive and negative battery cable clip (3) to the battery tray support bracket. 11.
Connect the positive and negative battery cable clip to the side of the battery tray support bracket.
12. Install the battery box.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System
Information > Service and Repair
Positive: Service and Repair
Battery Positive Cable Replacement (LNJ)
Removal Procedure
Important:
* Always use replacement cables that are of the same type, diameter and length of the cables that
you are replacing.
* Always route the replacement cable the same way as the original cable.
1. Remove the battery. 2. Remove the underhood bussed electrical center (UBEC) cover.
3. Remove the positive battery cable terminal nut (1) from the UBEC stud. 4. Remove the positive
battery cable terminal (2) from the UBEC stud.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System
Information > Service and Repair > Page 11504
5. Remove the battery box. 6. Disconnect the positive and negative battery cable clip (3) from the
battery tray support bracket. 7. Disconnect the positive and negative battery cable clip on the side
of the battery tray support bracket. 8. Raise and support the vehicle. Refer to Vehicle Lifting.
9. Remove the positive battery cable terminal to starter solenoid nut (1).
10. Remove the positive battery cable lead (2) from the starter solenoid. 11. Remove the battery
cable retainer (4) from the transaxle selector cable bracket. 12. Cut the tape and remove the
positive battery cable from the wire loom.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System
Information > Service and Repair > Page 11505
1. Install the positive battery cable to the wire loom and re-tape the loom. 2. Install the battery cable
retainer (4) to the transaxle selector cable bracket. 3. Install the positive battery cable lead (2) to
the starter solenoid.
Notice: Refer to Fastener Notice.
4. Install the positive battery cable terminal to starter solenoid nut (1).
Tighten the nut to 10 N.m (89 lb in).
5. Lower the vehicle.
6. Connect the positive and negative battery cable clip (3) to the battery tray support bracket. 7.
Connect the positive and negative battery cable clip to the side of the battery tray support bracket.
8. Install the battery box.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System
Information > Service and Repair > Page 11506
9. Install the positive battery cable terminal (2) to the UBEC stud.
10. Install the positive battery cable terminal nut (1) to the UBEC stud.
Tighten the nut to 15 N.m (11 lb ft).
11. Install the UBEC cover. 12. Install the battery.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations
Battery Current Sensor: Locations
Front of Vehicle/Engine Compartment Component Views
Left Front Engine Compartment Components 1 of 2
1 - Left Front Strut Tower 2 - G103 3 - Windshield Washer Fluid Pump 4 - Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 11510
Battery Current Sensor: Diagrams
Component Connector End Views
Battery Current Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 11511
Battery Current Sensor: Service and Repair
Battery Current Sensor Replacement
Removal Procedure
1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the
battery cable with tape for reference during installation. 3. Remove the tape securing the battery
current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips
and remove the clip from the cable. 5. Squeeze the negative battery cable branches together.
Important: Note the orientation of the battery current sensor prior to removal.
6. Slide the battery current sensor (1) off of the negative battery cable.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information >
Locations > Page 11512
1. Squeeze the negative battery cable branches together.
Important: Ensure the battery current sensor is installed in the correct direction and location on the
negative battery cable.
2. Slide the NEW battery current sensor (1) up onto the negative battery cable to the location
previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in
order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clip to
the cable to the locations previously marked during removal. 5. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement
Battery Tray: Service and Repair Battery Tray Replacement
Battery Tray Replacement
Removal Procedure
1. Remove the battery box. 2. Remove the battery tray support bracket bolt at the multiuse relay
and fuse bracket.
3. Remove the battery tray support bracket bolts. 4. Remove the battery tray support bracket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 11517
1. Position the battery tray support bracket.
Notice: Refer to Fastener Notice.
2. Install the battery tray support bracket bolts.
Tighten the bolts to 25 N.m (18 lb ft).
3. Install the battery tray support bracket bolt at the multiuse relay and fuse bracket.
Tighten the bolt to 25 N.m (18 lb ft).
4. Install the battery box. Refer to Battery Box Replacement.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 11518
Battery Tray: Service and Repair Battery Box Replacement
Battery Box Replacement
Removal Procedure
1. Remove the battery. 2. Remove the air conditioning (A/C) evaporator line clamp nut at the
battery box. 3. Remove the A/C evaporator outlet line clamp from the battery tray stud.
4. Remove the battery tray bolts. 5. Lift up the battery tray slightly in order to disconnect the battery
cooling air inlet duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 11519
6. Disconnect the battery cooling air inlet duct from the battery tray. 7. Remove the battery tray
from the vehicle.
Installation Procedure
1. Position the battery tray to the vehicle.
Important: Fully insert the duct into the hole on the battery tray past the second molded in ridge,
stopping at the flange.
2. Connect the battery cooling air inlet duct to the battery tray.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and
Repair > Battery Tray Replacement > Page 11520
3. Set the battery tray completely in place.
Notice: Refer to Fastener Notice.
4. Install the battery tray bolts.
Tighten the bolts to 15 N.m (11 lb ft).
5. Install the A/C evaporator outlet line clamp to the battery tray stud. 6. Install the A/C evaporator
line clamp nut at the battery tray.
Tighten the nut to 15 N.m (11 lb ft).
7. Install the battery.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications
Alternator: Specifications
Generator Usage
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 11525
Alternator: Diagrams
Component Connector End Views
Generator (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket and Engine Lift Bracket Replacement (LNJ)
Alternator: Service and Repair Generator Bracket and Engine Lift Bracket Replacement (LNJ)
Generator Bracket and Engine Lift Bracket Replacement (LNJ)
Removal Procedure
1. Remove the generator. 2. Remove the drive belt tensioner.
3. Remove the generator bracket bolts. 4. Remove the generator bracket.
Installation Procedure
1. Install the generator bracket.
Notice: Refer to Fastener Notice.
2. Install the generator bracket bolts.
Tighten the generator bracket bolts in the sequence shown to 50 N.m (37 lb ft).
3. Install the drive belt tensioner. 4. Install the generator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket and Engine Lift Bracket Replacement (LNJ) > Page 11528
Alternator: Service and Repair Generator Replacement (LNJ)
Generator Replacement (LNJ)
Removal Procedure
1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Disconnect the engine wiring
harness electrical connector (1) from the generator. 4. Reposition the engine wiring harness boot
(4). 5. Remove the generator terminal nut (2). 6. Remove the engine wiring harness terminal lead
(3) from the generator.
7. Remove the generator bolts (1). 8. Remove the generator (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket and Engine Lift Bracket Replacement (LNJ) > Page 11529
Installation Procedure
1. Install the generator (2).
Notice: Refer to Fastener Notice.
2. Install the generator bolts (1).
Tighten the bolts to 50 N.m (37 lb ft).
3. Install the engine wiring harness terminal lead (3) to the generator. 4. Install the generator
terminal nut (2).
Tighten the nut to 20 N.m (15 lb ft).
5. Position the engine wiring harness boot (4).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service
and Repair > Generator Bracket and Engine Lift Bracket Replacement (LNJ) > Page 11530
6. Connect the engine wiring harness electrical connector (1) to the generator. 7. Install the drive
belt. 8. Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid >
Component Information > Locations
Ignition Lock Solenoid: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid >
Component Information > Locations > Page 11536
Ignition Lock Solenoid: Diagrams
Component Connector End Views
Ignition Lock Solenoid
A/T Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: >
09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: Customer Interest Ignition - Key Difficult To Remove, Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: >
09-02-35-005C > Feb > 11 > Ignition - Key Difficult To Remove, Binds Or Sticks
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition - Key Difficult To Remove,
Binds Or Sticks
TECHNICAL
Bulletin No.: 09-02-35-005C
Date: February 07, 2011
Subject: Ignition Key Difficult to Remove, Ignition Key Binds or Sticks in Cylinder (Replace Ignition
Cylinder)
Models:
2005-2009 Chevrolet Cobalt (Built Prior to April 14, 2009) 2006-2010 Chevrolet HHR (Built Prior to
June 1, 2010) 2007-2009 Chevrolet Equinox (Built Prior to July 2008) 2005-2006 Pontiac Pursuit
(Canada Only) 2006-2009 Pontiac Solstice (Built Prior to April 14, 2009) 2007-2009 Pontiac G5
(Built Prior to April 14, 2009), Torrent (Built Prior to July 2008) 2006-2009 Saturn SKY (Built Prior to
April 24, 2009)
Supercede: This bulletin is being revised to remove an Attention statement, update the build date
for HHR and remove the CTS model. Please discard Corporate Bulletin Number 09-02-35-005B
(Section 02 - Steering).
Condition
Some customers may comment that the ignition key is difficult to remove or that the key sticks or
binds in the ignition cylinder.
Correction
A new ignition lock cylinder has been released to correct this concern. Replace the ignition lock
cylinder following the Ignition Lock Cylinder Replacement procedure in SI. For ignition lock cylinder
assembly and coding, use the instructions provided with the new cylinder.
Important To properly seat the new ignition lock cylinder into the housing, the key must be inserted
and turned to the RUN position.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures
Ignition Switch Lock Cylinder: Procedures
Key and Lock Cylinder Coding
Key Identification and Usage
The lock system used for this vehicle is a one key system with a key profile that has a two-sided
cut and milled grooves that are unique to this lock system. The teeth of the key locate the tumblers
and sidebar, flush to the outside of the lock cylinder from both sides of the cut.
Cutting Keys
The Exacta key cutting tool kit consists of a 10-position spacing plate, only positions two through
ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in
the instruction manual provided with the key cutting tool.
The customer information card or the retailer records will show the key code as a four-digit numeric
code. To determine the actual cut sequence of the key for this code, look up the code in the
appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The
ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key
to work properly in all the locks on the vehicle.
Determining Key Code with Exacta Cutter
1. Insert the key in the approved key cutting tool with the tip of the key against the stop. 2. With the
cutting die in the down position, move the carriage toward the die until it bottoms out. Record the
depth 1, 2, 3, or 4. 3. Repeat for each position.
Lock Cylinder Lubrication
Lubricate the lock cylinders with a light oil or graphite lubricant. Never use a silicon spray lubricant.
Lock Cylinder Tumblers
Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or
wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and
ignition tumblers represent 3 different series. There are also three different compression springs. It
is essential that the correct components be used in the tumbling of locks. The compression springs
are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler
wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the
tumbler wards then insert the tumbler springs on top of the tumblers.
Ignition Lock Cylinder Coding
Tools Required
J 41340 Lock Cylinder Holding Fixture and Staking Tool
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11553
Important: Ignition lock cylinder reads key cut position 1 through 9.
1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where
they will sit on top of the tumblers. 4. The seal plate (1) will be installed and crimped. 5. Insert the
seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only
when the two locator legs have been
properly inserted into the receptacles on the cylinder.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11554
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch
for the side bar to drop flush. If the side bar does
not drop flush, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the
cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer
and punch or chisel. 9. Repeat this stake on the areas of the cylinder directly opposite of the first to
stakes.
Door Lock Cylinder Coding
1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
Important: The door lock cylinder reads key cut position 4 through 9.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been
pre-assembled. The tumblers will have to be pushed past the
sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where
they will sit on top of the tumblers.
Balance of Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11555
1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into
position once the cylinder is inserted into the
housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and
pressing the cap until it bottoms out and snaps onto
the housing (2).
Glove Compartment Door Lock Cylinder Coding
1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11556
Important: When key is inserted into correct coded lock cylinder, all tumblers except the retainer is
flush with the lock cylinder.
3. Check coding of lock cylinder (4). Insert key.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11557
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder Case Replacement
Ignition Lock Cylinder Case Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Procedures > Page 11558
Ignition Lock Cylinder Replacement
Ignition Lock Cylinder Replacement
Removal Procedure
1. Disconnect the negative battery cable. 2. Disable the SIR system. Refer to SIR Disabling and
Enabling. 3. Remove the steering column trim covers. 4. Remove the wipers/washer switch. 5.
Turn the ignition lock cylinder to the RUN position.
Important: There are two retainers on the ignition lock cylinder. Depress both retainers to remove
the lock cylinder from the housing.
6. Depress the first retainer through the lock housing access hole (2) with a small allen wrench or
similar pick-type tool. The lock cylinder will back
out slightly.
7. Depress the second retainer through the lock housing access hole (1). The lock cylinder will
back out slightly again. 8. Pull the lock cylinder out enough to locate the second retainer to the lock
housing access hole (2). 9. Depress the retainer though the access hole (2) a second time. The
ignition cylinder should release from the housing. If not, the ignition cylinder
may need to be moved in and out several times to locate the retainer correctly in the hole.
10. Remove the lock cylinder from the lock housing.
Installation Procedure
Important: If you are installing a new lock cylinder, refer to Key and Lock Cylinder Coding.
1. Position the lock cylinder in the run position. Insert the cylinder into the lock housing. 2. Rotate
the lock cylinder in the housing. Verify proper rotation. 3. Install the wipers/washer switch. 4. Install
the steering column trim covers. 5. Enable the SIR system. Refer to SIR Disabling and Enabling. 6.
Connect the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information
Key: Technical Service Bulletins Locks - Key Code Security Rules and Information
INFORMATION
Bulletin No.: 10-00-89-010
Date: May 27, 2010
Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada
Only)
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior
Saturn and Saab 2002 and Prior Isuzu
Attention:
This bulletin has been created to address potential issues and questions regarding KeyCode
security. This bulletin should be read by all parties involved in KeyCode activity, including dealer
operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin
should be printed and maintained in the parts department for use as a reference.
Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009.
Where Are Key Codes Located?
General Motors provides access to KeyCodes through three sources when a vehicle is delivered to
a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a
small white bar coded tag sent with most new vehicles that also has the key code printed on it.
Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed
on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code
Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers.
The third source for Key codes is through the GM KeyCode Look-Up feature within the
OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model
years from the current model year.
When a vehicle is received by the dealership, care should be taken to safeguard the original
vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have
access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been
completed, the KeyCode information belongs to the customer and General Motors.
Tip
Only the original invoice contains key code information, a re-printed invoice does not.
GM KeyCode Look-Up Application for GM of Canada Dealers
All dealers should review the General Motors of Canada KeyCode Look-Up Policies and
Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates &
keys").
Please note that the KeyCode Access site is restricted. Only authorized users should be using this
application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently
goes back 17 years from current model year.
Important notes about security:
- Users may not access the system from multiple computers simultaneously.
- Users may only request one KeyCode at a time.
- KeyCode information will only be available on the screen for 2 minutes.
- Each user is personally responsible for maintaining and protecting their password.
- Never share your password with others.
- User Id's are suspended after 6 consecutive failed attempts.
- User Id's are disabled if not used for 90 days.
- Processes must be in place for regular dealership reviews.
- The Parts Manager (or assigned management) must have processes in place for employee
termination or life change events. Upon termination individuals access must be turned off
immediately and access should be re-evaluated upon any position changes within the dealership.
- If you think your password or ID security has been breached, contact Dealer Systems Support at
1-800-265-0573.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 11563
Each user will be required to accept the following agreement each time the KeyCode application is
used.
Key Code User Agreement
- Key codes are proprietary information belonging to General Motors Corporation and to the vehicle
owner.
- Unauthorized access to, or use of, key code information is unlawful and may subject the user to
criminal and civil penalties.
- This information should be treated as strictly confidential and should not be disclosed to anyone
unless authorized.
I will ensure that the following information is obtained prior to releasing any Key Code information:
1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership.
Registration should have normal markings from the Province that issued the registration and
possibly the
receipt for payment recorded as well.
Important
- GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving
out key codes.
- When the ownership of the vehicle is in doubt, dealership personnel should not provide the
information.
Key code requests should never be received via a fax or the internet and key codes should never
be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the
expected manner that dealers will use to release a key code or as otherwise stipulated in this
bulletin or other materials.
- Key codes should NEVER be sent via a fax or the internet.
- Each Dealership should create a permanent file to document all KeyCode Look Up transactions.
Requests should be filed by VIN and in each folder retain copies of the following:
- Government issued picture ID (Drivers License)
- Registration or other proof of ownership.
- Copy of the paid customer receipt which has the name of the employee who cut and sold the key
to the customer.
- Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up
to either GM or law enforcement officials.
- Dealership Management has the ability to review all KeyCode Look-Up transactions.
- Dealership KeyCode documentation must be retained for two years.
Frequently Asked Questions (FAQs) for GM of Canada Dealers
How do I request a KeyCode for customer owned vehicle that is not registered?
Scrapped, salvaged or stored vehicles that do not have a current registration should still have the
ownership verified by requesting the vehicle title, current insurance policy and / or current lien
holder information from the customers financing source. If you cannot determine if the customer is
the owner of the vehicle, do not provide the key code information. In these cases, a short
description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on
file. Any clarifying explanation should be entered into the comments field.
How do I document a KeyCode request for a vehicle that is being repossessed?
The repossessor must document ownership of the vehicle by providing a court ordered
repossession order and lien-holder documents prior to providing key code information. Copies of
the repossessors Drivers License and a business card should be retained by the dealership for
documentation.
What do I do if the registration information is locked in the vehicle?
Every effort should be made to obtain complete information for each request. Each Dealership will
have to decide on a case by case basis if enough information is available to verify the customer's
ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and
or current lien information from the customers financing source. Dealership Management must be
involved in any request without complete information. If you cannot determine if the customer is the
owner of the vehicle, do not provide the key code information.
Can I get a print out of the information on the screen?
It is important to note that the Key Code Look Up Search Results contain sensitive and/or
proprietary information. For this reason GM recommends against printing it. If the Search Results
must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper
or illegal use.
Who in the dealership has access to the KeyCode application?
Dealership Parts Manager (or assigned management) will determine, and control, who is
authorized to access the KeyCode Look Up application. However, we anticipate that dealership
parts and service management will be the primary users of the application. The KeyCode Look Up
application automatically tracks each user activity session. Information tracked by the system
includes: User name, User ID, all other entered data and the date/time of access.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 11564
What if I input the VIN incorrectly?
If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN
or that the VIN has been entered incorrectly) the system will return an error message.
If I am an authorized user for the KeyCode application, can I access the application from home?
Yes.
What if I suspect key code misuse?
Your dealership should communicate the proper procedures for requesting key codes. Any
suspicious activity either within the dealership or externally should be reported to Dealer Systems
Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
Whose key codes can I access through the system?
At this time the following Canadian vehicle codes are available through the system: Chevrolet,
Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu
(up to 2002 model year) for a maximum of 17 model years.
What should I do if I enter a valid VIN and the system does not produce any key code information?
Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This
may be the result of new vehicle information not yet available. In addition, older vehicle information
may have been sent to an archive status. If you do not receive a key code returned for valid VIN,
you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
How do I access KeyCodes if the KeyCode Look-up system is down?
If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling
dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have
the customer contact Roadside assistance, OnStar if subscribed, or 911.
What should I do if the KeyCode from the look-up system does not work on the vehicle?
On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In
cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting
equipment that the key has been cut correctly. If the key has been cut correctly you may be able to
verify the proper KeyCode was given through the original selling dealer. When unable to verify the
KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock
cylinder may have been changed. In these situations following the proper SI document for recoding
a key or replacing the lock cylinder may be necessary.
How long do I have to keep KeyCode Records?
Dealership KeyCode documentation must be retained for two years.
Can I get a KeyCode changed in the Look-Up system?
Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed.
Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
What information do I need before I can provide a driver of a company fleet vehicle Keys or
KeyCode information?
The dealership should have a copy of the individual's driver's license, proof of employment and
registration. If there is any question as to the customer's employment by the fleet company, the
dealer should attempt to contact the fleet company for verification. If there is not enough
information to determine ownership and employment, this information should not be provided.
How do I document a request from an Independent Repair facility for a KeyCode or Key?
The independent must provide a copy of their driver's license, proof of employment and signed
copy of the repair order for that repair facility. The repair order must include customer's name,
address, VIN, city, province and license plate number. Copies of this information must be included
in your dealer KeyCode file.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical
Service Bulletins > Locks - Key Code Security Rules and Information > Page 11565
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip
Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter
Diagnostic Tip
INFORMATION
Bulletin No.: 09-08-52-004A
Date: January 08, 2010
Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter
When Transmitter Battery is Weak or Dead
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade
ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR,
Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra,
Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn
AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories).
Follow these procedures if a customer comments that their GM Accessory 2-way transmitter
stopped communicating with the vehicle.
About GM Accessory 2-Way Remote Start
The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a
2-way advanced remote start system, but often the 2-way transmitter may only be coded to one
vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter
will enter second vehicle mode and will not control the original vehicle until a subsequent double
press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of
the 2-way transmitter should be thought of as an individual transmitter with its own unique code.
Test the Transmitter Battery
Note
This test should be performed prior to releasing the vehicle or transmitter to the customer.
All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or
replacement of a transmitter battery using the following procedure.
1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of
the unlock button, observe the battery gauge located in the upper right corner of the LCD display.
The gauge should read
full (three bars inside the battery icon).
If after having a new battery installed, the battery goes dead within five months, the transmitter
could have high sleep current, causing the battery to go dead. Replace the transmitter.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition
exhibited is resolved without completing every step, the remaining steps do not need to be
performed.
Determine if Transmitter is in Second Vehicle Mode
1. Press and release any of the face buttons on the 2-way transmitter and observe the display on
power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be
displayed on the left side of the transmitter display. Is the 2-way
transmitter in second vehicle mode?
If Yes, the 2-way transmitter is working properly.
- Press and release the left side button twice within one second. The 2-way transmitter should exit
second vehicle mode.
- Press and release the lock button. Press and release the unlock button.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 11571
- Confirm that the vehicle responds with the appropriate lock and unlock function.
- If Yes , the 2-way transmitter was in mode B.
- Press and release the left side button twice within one second. The 2-way transmitter should
enter second vehicle mode.
- Use the "next available slot" method in the scan tool to program the 2-way transmitter to the
2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI.
- Both vehicle modes of the 2-way transmitter should now be coded to the vehicle.
If No:
The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal
diagnostic procedures.
Parts Information
For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts
Catalog or Corporate Bulletin Number 09-00-89-025A.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 11572
Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote
Start
INFORMATION
Bulletin No.: 09-00-89-025A
Date: October 26, 2009
Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT
2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche,
Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse
2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent
2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA,
OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY
Attention:
This bulletin does not apply to GMODC dealers.
Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin
Number 09-00-89-025 (Section 00 - General Information).
This bulletin is being published to provide information on locating service part numbers for GM
Accessory, 2-Way Advanced Remote Start Systems.
Dealers should consult the chart below and use the correct service part. Dealers should not use
entire kit for warranty or repair work.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 11573
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 11574
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 11575
Parts Information
Service parts common to all 2-Way Advanced Remote Start Systems
Transmitter Battery 12493150
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Diagrams
Starter Motor: Diagrams
Component Connector End Views - Continued
Starter (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Diagrams > Page 11579
Starter Motor: Service and Repair
Starter Motor Replacement (LNJ)
Removal Procedure
1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to
Vehicle Lifting. 3. Disconnect the engine wiring harness electrical connector (4) from the starter. 4.
Remove the starter solenoid nut (3). 5. Remove the positive battery cable terminal (2) and the
engine wiring harness terminal (1) from the starter solenoid.
6. Remove the torque converter cover bolt (2). 7. Remove the torque converter cover (1).
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Diagrams > Page 11580
8. Remove the starter motor bolts (2, 3). 9. Remove the starter motor (1).
Installation Procedure
1. Install the starter motor (1).
Notice: Refer to Fastener Notice.
2. Install the starter motor bolts (2, 3).
Tighten the bolts to 43 N.m (32 lb ft).
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3. Install the torque converter cover (1). 4. Install the torque converter cover bolt (2).
Tighten the bolt to 8 N.m (71 lb in).
5. Install the engine wiring harness terminal (1) and the positive battery cable terminal (2) to the
starter solenoid. 6. Install the starter solenoid nut (3).
Tighten the nut to 10 N.m (89 lb in).
7. Connect the engine wiring harness electrical connector (4) to the starter. 8. Lower the vehicle. 9.
Install the negative battery cable.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information >
Locations
Starter Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Locations
Starter Solenoid: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11593
Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Component Information > Diagrams > Diagram Information and Instructions > Page 11594
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11595
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Component Information > Diagrams > Diagram Information and Instructions > Page 11596
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Component Information > Diagrams > Diagram Information and Instructions > Page 11597
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11598
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11599
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11678
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11679
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11680
13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11681
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11682
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11683
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11684
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Component Information > Diagrams > Diagram Information and Instructions > Page 11685
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11686
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11687
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11688
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Component Information > Diagrams > Diagram Information and Instructions > Page 11689
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Diagram Information and Instructions > Page 11690
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet >
Component Information > Diagrams > Diagram Information and Instructions > Page 11691
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Auxiliary Power Outlet - Console 1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Page 11692
Auxiliary Power Outlet: Service and Repair
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigar Lighter Socket Remover
Removal Procedure
1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle:
1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the
front of the receptacle. The J 42059 pushes the
plastic latches from these tab windows and the receptacle can be pulled straight out.
2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit
straight into the receptacle. Angle the J 42059
slightly for insertion into the receptacle.
3. Insert the other side of the "T" into the opposite tab window.
You must move the J 42059 handle toward horizontal to engage the other tab window.
4. Use the J 42059 to pull the receptacle straight out.
3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate
method:
1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in
the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Page 11693
1. Route the connector through the retainer. Align the accessory power receptacle retainer to the
slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the
electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer.
Install the accessory power receptacle by pressing into place until fully seated. 5. Install the
accessory power receptacle fuse.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Component Information > Diagrams > Page 11694
Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Branching Point > Component
Information > Diagrams
Branching Point: Diagrams
Splice Pack Connector End Views
JX200
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11706
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11712
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Electrical - Aftermarket Fuse Warning
Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the fuse block cover, push in on the tabs located on the rear of the cover, and lift. To
reinstall, fit together the tabs located on the front of the cover, and push down on the cover until the
tabs on the rear of the cover click into place.
Notice: Spilling liquid on any electrical components on your vehicle may damage it. Always keep
the covers on any electrical component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Locations > Engine Compartment Fuse Block > Page 11719
FUSES - USAGE
Fuse 1 ..................................................................................................................................................
........................................................ Cooling Fan 2 Fuse 2 .................................................................
......................................................................................................................................... Cooling Fan
1 Fuse 3 ...............................................................................................................................................
........................................................ Auxiliary Power Fuse 4 ...............................................................
.............................................................................................................................................. Rear
HVAC Fuse 5 .......................................................................................................................................
................................................................................. Spare Fuse 6 .....................................................
..............................................................................................................................................................
..... Spare Fuse 7 .................................................................................................................................
........................................................... Antilock Brake System Fuse 8 .................................................
......................................................................................................................................... Air
Conditioning Clutch Fuse 9 .................................................................................................................
........................................................................... Driver Side Low-Beam Fuse 10 ...............................
.......................................................................................................................................................
Daytime Running Lamp 2 Fuse 11 ......................................................................................................
.............................................................................. Passenger Side High-Beam Fuse 12 ...................
..............................................................................................................................................................
.... Passenger Side Park Lamp Fuse 13 ..............................................................................................
......................................................................................................................... Horn Fuse 14 .............
..............................................................................................................................................................
............... Driver Side Park Lamp Fuse 15 ..........................................................................................
.......................................................................................................................... Starter Fuse 16
............................................................................................................................................ Electronic
Throttle Control, Engine Control Module Fuse 17 ...............................................................................
.................................................................................................................. Emission Device 1 Fuse
18 .........................................................................................................................................................
..................................... Even Coils, Injectors Fuse 19 ........................................................................
....................................................................................................................... Odd Coils, Injectors
Fuse 20 ................................................................................................................................................
................................................. Emission Device 2 Fuse 21 ...............................................................
.......................................................................................................................................................
Spare Fuse 22 .....................................................................................................................................
................................ Powertrain Control Module, Ignition Fuse 23 .....................................................
.....................................................................................................................................................
Transmission Fuse 24 .........................................................................................................................
.................................................................... Mass Airflow Sensor Fuse 25 .........................................
..............................................................................................................................................................
Airbag Display Fuse 26 .......................................................................................................................
............................................................................................... Spare Fuse 27 .....................................
..............................................................................................................................................................
............. Stoplamp
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Locations > Engine Compartment Fuse Block > Page 11720
Fuse 28 ................................................................................................................................................
.................................... Passenger Side Low-Beam Fuse 29 ..............................................................
........................................................................................................................... Driver Side
High-Beam Fuse 30 .............................................................................................................................
.......................................................................... Battery Main 3 Fuse 32 ............................................
..............................................................................................................................................................
............ Spare Fuse 33 ........................................................................................................................
.................................................... Engine Control Module, Battery Fuse 34 ........................................
.......................................................................................................................... Transmission Control
Module, Battery Fuse 35 .....................................................................................................................
............................................................................. Trailer Park Lamp Fuse 36 ....................................
..............................................................................................................................................................
......... Front Wiper Fuse 37
............................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Fuse 38 .............................................................................
......................................................................................................................................... Spare Fuse
39 .........................................................................................................................................................
..................................................... Fuel Pump Fuse 40 .......................................................................
......................................................................................................................................... Not Used
Fuse 41 ................................................................................................................................................
.................................................... All-Wheel Drive Fuse 42 .................................................................
................................................................................................................... Regulated Voltage
Control Fuse 43
......................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Fuse 44 .....................................................................
................................................................................................................................................. Spare
Fuse 45 ................................................................................................................................................
................................................ Front, Rear Washer Fuse 48 ..............................................................
.......................................................................................................................................... Rear
Defogger Fuse 49 ................................................................................................................................
............................................... Antilock Brake System Motor Fuse 50 ................................................
.......................................................................................................................................................
Battery Main 2 Fuse 52 .......................................................................................................................
................................................................ Daytime Running Lamps Fuse 53 ......................................
..............................................................................................................................................................
......... Fog Lamps Fuse 54 ...................................................................................................................
......................................................... Climate Control System Blower Fuse 57 ...................................
..............................................................................................................................................................
...... Battery Main 1 Fuse 63 ................................................................................................................
......................................................................... Electric Power Steering
RELAYS - USAGE
Relay 31 ..............................................................................................................................................
......................................................... Ignition Main Relay 46 ...............................................................
.................................................................................................... Air Conditioning Compressor
Clutch Relay 47 ...................................................................................................................................
......................................................................... Powertrain Relay 51 ..................................................
..............................................................................................................................................................
.... Spare Relay 55 ...............................................................................................................................
..................................................................................... Crank Relay 56 ..............................................
..............................................................................................................................................................
........ Fan 1 Relay 58
.....................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Relay 59
..........................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Relay 60 ............................................................................
........................................................................................................................................ Fan 3 Relay
61 .........................................................................................................................................................
........................................................... Fan 2 Relay 62 ........................................................................
.................................................................................................................................... Fuel Pump
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11721
Fuse: Locations Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11722
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11723
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11724
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11725
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Engine Compartment Fuse Block > Page 11726
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 11729
Fuse: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 11730
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 11731
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 11732
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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Diagrams > Diagram Information and Instructions > Page 11733
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Diagrams > Diagram Information and Instructions > Page 11734
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Diagrams > Diagram Information and Instructions > Page 11735
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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Diagrams > Diagram Information and Instructions > Page 11736
to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagrams > Diagram Information and Instructions > Page 11818
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagrams > Diagram Information and Instructions > Page 11822
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagrams > Diagram Information and Instructions > Page 11824
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagrams > Diagram Information and Instructions > Page 11826
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Underhood Fuse Block
Fuse: Application and ID Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Application and ID > Underhood Fuse Block > Page 11829
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Application and ID > Underhood Fuse Block > Page 11830
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Application and ID > Underhood Fuse Block > Page 11831
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Application and ID > Underhood Fuse Block > Page 11832
Fuse: Application and ID Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Application and ID > Underhood Fuse Block > Page 11833
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations
Fuse Block: Locations
Front of Vehicle/Engine Compartment Component Views
Front Engine Compartment Components
1 - Fuse Block - Underhood 2 - Battery 3 - Cooling Fan - Left 4 - Cooling Fan - Right
Left Front Engine Compartment Components 2 of 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations > Page 11837
1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information > Diagrams > Diagram Information and Instructions > Page 11841
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11881
4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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Information > Diagrams > Diagram Information and Instructions > Page 11882
1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11883
1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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Information > Diagrams > Diagram Information and Instructions > Page 11884
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Information > Diagrams > Diagram Information and Instructions > Page 11885
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11886
9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11887
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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Information > Diagrams > Diagram Information and Instructions > Page 11888
4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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Information > Diagrams > Diagram Information and Instructions > Page 11889
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 11890
2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11891
Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Information > Diagrams > Diagram Information and Instructions > Page 11892
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 11894
3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11895
5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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Information > Diagrams > Diagram Information and Instructions > Page 11896
8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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Information > Diagrams > Diagram Information and Instructions > Page 11897
2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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Information > Diagrams > Diagram Information and Instructions > Page 11898
4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Information > Diagrams > Diagram Information and Instructions > Page 11899
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Information > Diagrams > Diagram Information and Instructions > Page 11900
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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Information > Diagrams > Diagram Information and Instructions > Page 11901
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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Information > Diagrams > Diagram Information and Instructions > Page 11903
5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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Information > Diagrams > Diagram Information and Instructions > Page 11904
7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11905
9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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Information > Diagrams > Diagram Information and Instructions > Page 11906
3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 11907
7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 11909
4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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Information > Diagrams > Diagram Information and Instructions > Page 11910
6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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Information > Diagrams > Diagram Information and Instructions > Page 11911
2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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Information > Diagrams > Diagram Information and Instructions > Page 11912
2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 11913
5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Information > Diagrams > Diagram Information and Instructions > Page 11914
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11915
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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Information > Diagrams > Diagram Information and Instructions > Page 11916
View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 11930
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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Information > Diagrams > Diagram Information and Instructions > Page 11931
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11932
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11933
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11934
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11935
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11936
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11937
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11938
Fuse Block: Connector Views
Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11939
Fuse Block - Underhood X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11940
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11941
Fuse Block - Underhood X2 (Pin 1 To 41)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11942
Fuse Block - Underhood X2 (Pin 42 To C)
Fuse Block - Underhood X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11943
Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11944
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11945
Fuse Block - Instrument Panel X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11946
Fuse Block - Instrument Panel X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11947
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11948
Fuse Block - Instrument Panel X3 (Pin 1 To 38)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 11949
Fuse Block - Instrument Panel X3 (Pin 39 To C)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement
Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
Instrument Panel Electrical Center or Junction Block Replacement
Removal Procedure
Important: Record all preset radio stations.
1. Turn the ignition OFF. 2. Remove the screws from the battery cooling box. Remove the battery
cover. 3. Disconnect the negative battery cable. 4. Disconnect the positive battery cable. 5.
Remove the console.
6. Remove the nut holding the following fuse block connectors to the back of the I/P fuse block (4):
* The body connector (1)
* The I/P connector (2)
* The I/P connector (3)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 11952
7. Remove the bolt holding the fuse block into place. 8. Remove the ground wire (1). 9. Remove
the fuse block.
Installation Procedure
Notice: Refer to Fastener Notice.
1. Install the fuse block and attach the ground wire (1) and attach the bolt.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 11953
2. Connect the harness connectors to the back of the I/P fuse block (4).
Tighten the connectors to 4 N.m (35 lb in).
3. Install the console. 4. Connect the positive battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
5. Connect the negative battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
6. Install the battery cooling box cover and install the screws.
Tighten the screws to 2 N.m (18 lb in).
7. Set the radio stations to the preset selections.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 11954
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement
Underhood Electrical Center or Junction Block Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Service and Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 11955
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket
Replacement
Underhood Electrical Center or Junction Block Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair
Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11960
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11961
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11962
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11963
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11964
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component
Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 11965
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D
> Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11974
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC
P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: >
07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11980
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199
Multiple Junction Connector: Diagrams X100 - X199
X103
Inline Harness Connector End Views
X103 Left Front Wheel Speed Sensor Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Right Front Wheel Speed Sensor Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11983
X106
Inline Harness Connector End Views
X106 Body Harness to the Engine Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11984
X101
Inline Harness Connector End Views
X101 Body Harness to the Forward Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11985
X102
Inline Harness Connector End Views
X102 Body Harness to the Battery Cable Harness
X105
Inline Harness Connector End Views
X105 Engine Harness to the Fuel Injector Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11986
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to the Right Cooling Fan Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11987
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11988
Multiple Junction Connector: Diagrams X200 - X299
X204
Inline Harness Connector End Views
X204 Instrument Panel Harness to the Body Harness
X206
Inline Harness Connector End Views
X206 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11989
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11990
X206 Instrument Panel Harness To The Body Harness (Pin 1 To 19)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11991
X206 Instrument Panel Harness To The Body Harness (Pin 20 To 26)
X207
Inline Harness Connector End Views
X207 Console Harness to the Instrument Panel Harness (UUC -C69)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11992
X214
Inline Harness Connector End Views
X214 Passenger Airbag Jumper Harness to the Instrument Panel Harness
X218
Inline Harness Connector End Views
X218 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11993
X219
Inline Harness Connector End Views
X219 Body Harness to the Instrument Panel Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11994
X226
Inline Harness Connector End Views
X226 Instrument Panel Harness to the Shifter Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11995
X210
Inline Harness Connector End Views
X210 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11996
X275
Inline Harness Connector End Views
X275 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11997
X276
Inline Harness Connector End Views
X276 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11998
X277
Inline Harness Connector End Views
X277 Steering Wheel Controls Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 11999
X216
Inline Harness Connector End Views
X216 Instrument Panel Harness to the HVAC Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12000
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12001
Multiple Junction Connector: Diagrams X300 - X399
X305
Inline Harness Connector End Views
X305 Console Harness to the Body Harness
X308
Inline Harness Connector End Views
X308 Body Harness to the Power Seat Harness (AG1 -KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12002
X308 Body Harness to the Driver Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12003
X309
Inline Harness Connector End Views
X309 Body Harness to the Passenger Seat Harness (-KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12004
X309 Body Harness to the Passenger Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12005
X311
Inline Harness Connector End Views
X311 Headliner Harness to the Sunshade Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12006
X312
Inline Harness Connector End Views
X312 Driver Seat Harness to the Power Seat Harness (AG1 +KA1)
X313
Inline Harness Connector End Views
X313 Passenger Presence Harness to the Passenger Seat Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12007
X314
Inline Harness Connector End Views
X314 Headliner Harness to the Sunroof Harness (CF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12008
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12009
Multiple Junction Connector: Diagrams X400 - X499
X400
Inline Harness Connector End Views
X400 Body Harness to the Chassis Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12010
X403
Inline Harness Connector End Views
X403 Body Harness to the Left Tail Lamp Harness
X404
Inline Harness Connector End Views
X404 Body Harness to the Right Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12011
X401
Inline Harness Connector End Views
X401 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12012
X405
Inline Harness Connector End Views
X405 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12013
X406
Inline Harness Connector End Views
X406 Body Harness to the Fuel Sender Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12014
X409
Inline Harness Connector End Views
X409 Body Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12015
X410
Inline Harness Connector End Views
X410 Trailer Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12016
X412
Inline Harness Connector End Views
X412 Headliner to the Instrument Panel Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12017
X414
Inline Harness Connector End Views
X414 Body to the CHMSL Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12018
X415
Inline Harness Connector End Views
X415 Headliner Harness to the Body Harness
X417
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12019
Inline Harness Connector End Views
X417 Headliner Harness to the Body Harness (U3U)
X420
Inline Harness Connector End Views
X420 Body Harness to the Left Inflatable Restraint Roof Rail Module Harness (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12020
X421
Inline Harness Connector End Views
X421 Body Harness to the Right Inflatable Restraint Roof Rail Module Harness (ASF)
X422
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12021
Inline Harness Connector End Views
X422 Headliner Harness to the Body Harness (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12022
Multiple Junction Connector: Diagrams
X103
Inline Harness Connector End Views
X103 Left Front Wheel Speed Sensor Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Right Front Wheel Speed Sensor Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12023
X106
Inline Harness Connector End Views
X106 Body Harness to the Engine Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12024
X101
Inline Harness Connector End Views
X101 Body Harness to the Forward Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12025
X102
Inline Harness Connector End Views
X102 Body Harness to the Battery Cable Harness
X105
Inline Harness Connector End Views
X105 Engine Harness to the Fuel Injector Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12026
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to the Right Cooling Fan Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12027
X204
Inline Harness Connector End Views
X204 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12028
X206
Inline Harness Connector End Views
X206 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12029
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12030
X206 Instrument Panel Harness To The Body Harness (Pin 1 To 19)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12031
X206 Instrument Panel Harness To The Body Harness (Pin 20 To 26)
X207
Inline Harness Connector End Views
X207 Console Harness to the Instrument Panel Harness (UUC -C69)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12032
X214
Inline Harness Connector End Views
X214 Passenger Airbag Jumper Harness to the Instrument Panel Harness
X218
Inline Harness Connector End Views
X218 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12033
X219
Inline Harness Connector End Views
X219 Body Harness to the Instrument Panel Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12034
X226
Inline Harness Connector End Views
X226 Instrument Panel Harness to the Shifter Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12035
X210
Inline Harness Connector End Views
X210 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12036
X275
Inline Harness Connector End Views
X275 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12037
X276
Inline Harness Connector End Views
X276 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12038
X277
Inline Harness Connector End Views
X277 Steering Wheel Controls Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12039
X216
Inline Harness Connector End Views
X216 Instrument Panel Harness to the HVAC Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12040
X305
Inline Harness Connector End Views
X305 Console Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12041
X308
Inline Harness Connector End Views
X308 Body Harness to the Power Seat Harness (AG1 -KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12042
X308 Body Harness to the Driver Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12043
X309
Inline Harness Connector End Views
X309 Body Harness to the Passenger Seat Harness (-KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12044
X309 Body Harness to the Passenger Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12045
X311
Inline Harness Connector End Views
X311 Headliner Harness to the Sunshade Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12046
X312
Inline Harness Connector End Views
X312 Driver Seat Harness to the Power Seat Harness (AG1 +KA1)
X313
Inline Harness Connector End Views
X313 Passenger Presence Harness to the Passenger Seat Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12047
X314
Inline Harness Connector End Views
X314 Headliner Harness to the Sunroof Harness (CF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12048
X400
Inline Harness Connector End Views
X400 Body Harness to the Chassis Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12049
X403
Inline Harness Connector End Views
X403 Body Harness to the Left Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12050
X404
Inline Harness Connector End Views
X404 Body Harness to the Right Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12051
X401
Inline Harness Connector End Views
X401 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12052
X405
Inline Harness Connector End Views
X405 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12053
X406
Inline Harness Connector End Views
X406 Body Harness to the Fuel Sender Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12054
X409
Inline Harness Connector End Views
X409 Body Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12055
X410
Inline Harness Connector End Views
X410 Trailer Harness to the Trailer Jumper Harness (V92)
X412
Inline Harness Connector End Views
X412 Headliner to the Instrument Panel Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12056
X414
Inline Harness Connector End Views
X414 Body to the CHMSL Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12057
X415
Inline Harness Connector End Views
X415 Headliner Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12058
X417
Inline Harness Connector End Views
X417 Headliner Harness to the Body Harness (U3U)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12059
X420
Inline Harness Connector End Views
X420 Body Harness to the Left Inflatable Restraint Roof Rail Module Harness (ASF)
X421
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12060
Inline Harness Connector End Views
X421 Body Harness to the Right Inflatable Restraint Roof Rail Module Harness (ASF)
X422
Inline Harness Connector End Views
X422 Headliner Harness to the Body Harness (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12061
X500 - X599
Inline Harness Connector End Views
X500 Body Harness to the Left Front Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12062
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12063
X600 - X699
Inline Harness Connector End Views
X600 Body Harness to the Right Front Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12064
X700 - X799
Inline Harness Connector End Views
X700 Body Harness to the Left Rear Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12065
X800 - X899
Inline Harness Connector End Views
X800 Body Harness to the Right Rear Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12066
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12067
X902
Inline Harness Connector End Views
X902 Liftgate Jumper to Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12068
X906
Inline Harness Connector End Views
X906 Liftgate Jumper to Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12069
X907
Inline Harness Connector End Views
X907 License Lamp Harness to the Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12070
X908
Inline Harness Connector End Views
X908 License Lamp Harness to the Liftgate Harness
X911
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > X100 - X199 > Page 12071
Inline Harness Connector End Views
X911 CHMSL Jumper Harness to the CHMSL Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12076
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12077
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 12083
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement
(Attached to Wire Harness) > Page 12084
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules
Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 12093
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 12094
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set
By Various Control Modules > Page 12095
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power
Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power > Page 12100
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12106
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12107
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10
> Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12108
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12113
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12114
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12115
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12116
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12117
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10
> Electrical - Information For Electrical Ground Repair > Page 12118
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10
> Electrical - Intermittent MIL/DTC P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10
> Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12123
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 12129
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 >
Electrical - Information For Electrical Ground Repair > Page 12130
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
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Electrical - Information For Electrical Ground Repair > Page 12131
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
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5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
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Electrical - Information For Electrical Ground Repair > Page 12133
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
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For vehicles repaired under warranty, use the table.
Disclaimer
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Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Auxiliary Power Outlet: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagrams > Diagram Information and Instructions > Page 12233
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagrams > Diagram Information and Instructions > Page 12235
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagrams > Diagram Information and Instructions > Page 12236
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Diagrams > Diagram Information and Instructions > Page 12237
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Diagrams > Diagram Information and Instructions > Page 12238
Auxiliary Power Outlet: Connector Views
Component Connector End Views
Auxiliary Power Outlet - Console 1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Auxiliary Power Outlet: Service and Repair
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigar Lighter Socket Remover
Removal Procedure
1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle:
1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the
front of the receptacle. The J 42059 pushes the
plastic latches from these tab windows and the receptacle can be pulled straight out.
2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit
straight into the receptacle. Angle the J 42059
slightly for insertion into the receptacle.
3. Insert the other side of the "T" into the opposite tab window.
You must move the J 42059 handle toward horizontal to engage the other tab window.
4. Use the J 42059 to pull the receptacle straight out.
3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate
method:
1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in
the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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1. Route the connector through the retainer. Align the accessory power receptacle retainer to the
slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the
electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer.
Install the accessory power receptacle by pressing into place until fully seated. 5. Install the
accessory power receptacle fuse.
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Auxiliary Power Outlet: Tools and Equipment
Special Tools
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Branching Point > Component Information > Diagrams
Branching Point: Diagrams
Splice Pack Connector End Views
JX200
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R)
Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio
System - Noise When Using OnStar(R) > Page 12253
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R)
Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 >
Audio System - Noise When Using OnStar(R) > Page 12259
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service
Bulletins > Electrical - Aftermarket Fuse Warning
Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning
Bulletin No.: 07-08-45-002
Date: September 05, 2007
ADVANCED SERVICE INFORMATION
Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and
Prior HUMMER H2, H3 2008 and Prior Saab 9-7X
Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses
General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a
variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring
system of the vehicles they were customer installed in.
Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted
directly across the battery terminals.
How to Identify These Fuses
Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage
stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There
are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed
by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It
would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring
overheating is found you should check the fuse panel for the presence of this style of fuse.
All GM dealers should use genuine GM fuses on the vehicles they service. You should also
encourage the use of GM fuses to your customers to assure they are getting the required electrical
system protection. GM has no knowledge of any concerns with other aftermarket fuses. If
additional information becomes available, this bulletin will be updated.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Engine
Compartment Fuse Block
Fuse: Locations Engine Compartment Fuse Block
ENGINE COMPARTMENT FUSE BLOCK
The engine compartment fuse block is located on the driver side of the engine compartment.
To remove the fuse block cover, push in on the tabs located on the rear of the cover, and lift. To
reinstall, fit together the tabs located on the front of the cover, and push down on the cover until the
tabs on the rear of the cover click into place.
Notice: Spilling liquid on any electrical components on your vehicle may damage it. Always keep
the covers on any electrical component.
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FUSES - USAGE
Fuse 1 ..................................................................................................................................................
........................................................ Cooling Fan 2 Fuse 2 .................................................................
......................................................................................................................................... Cooling Fan
1 Fuse 3 ...............................................................................................................................................
........................................................ Auxiliary Power Fuse 4 ...............................................................
.............................................................................................................................................. Rear
HVAC Fuse 5 .......................................................................................................................................
................................................................................. Spare Fuse 6 .....................................................
..............................................................................................................................................................
..... Spare Fuse 7 .................................................................................................................................
........................................................... Antilock Brake System Fuse 8 .................................................
......................................................................................................................................... Air
Conditioning Clutch Fuse 9 .................................................................................................................
........................................................................... Driver Side Low-Beam Fuse 10 ...............................
.......................................................................................................................................................
Daytime Running Lamp 2 Fuse 11 ......................................................................................................
.............................................................................. Passenger Side High-Beam Fuse 12 ...................
..............................................................................................................................................................
.... Passenger Side Park Lamp Fuse 13 ..............................................................................................
......................................................................................................................... Horn Fuse 14 .............
..............................................................................................................................................................
............... Driver Side Park Lamp Fuse 15 ..........................................................................................
.......................................................................................................................... Starter Fuse 16
............................................................................................................................................ Electronic
Throttle Control, Engine Control Module Fuse 17 ...............................................................................
.................................................................................................................. Emission Device 1 Fuse
18 .........................................................................................................................................................
..................................... Even Coils, Injectors Fuse 19 ........................................................................
....................................................................................................................... Odd Coils, Injectors
Fuse 20 ................................................................................................................................................
................................................. Emission Device 2 Fuse 21 ...............................................................
.......................................................................................................................................................
Spare Fuse 22 .....................................................................................................................................
................................ Powertrain Control Module, Ignition Fuse 23 .....................................................
.....................................................................................................................................................
Transmission Fuse 24 .........................................................................................................................
.................................................................... Mass Airflow Sensor Fuse 25 .........................................
..............................................................................................................................................................
Airbag Display Fuse 26 .......................................................................................................................
............................................................................................... Spare Fuse 27 .....................................
..............................................................................................................................................................
............. Stoplamp
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Fuse 28 ................................................................................................................................................
.................................... Passenger Side Low-Beam Fuse 29 ..............................................................
........................................................................................................................... Driver Side
High-Beam Fuse 30 .............................................................................................................................
.......................................................................... Battery Main 3 Fuse 32 ............................................
..............................................................................................................................................................
............ Spare Fuse 33 ........................................................................................................................
.................................................... Engine Control Module, Battery Fuse 34 ........................................
.......................................................................................................................... Transmission Control
Module, Battery Fuse 35 .....................................................................................................................
............................................................................. Trailer Park Lamp Fuse 36 ....................................
..............................................................................................................................................................
......... Front Wiper Fuse 37
............................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Fuse 38 .............................................................................
......................................................................................................................................... Spare Fuse
39 .........................................................................................................................................................
..................................................... Fuel Pump Fuse 40 .......................................................................
......................................................................................................................................... Not Used
Fuse 41 ................................................................................................................................................
.................................................... All-Wheel Drive Fuse 42 .................................................................
................................................................................................................... Regulated Voltage
Control Fuse 43
......................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Fuse 44 .....................................................................
................................................................................................................................................. Spare
Fuse 45 ................................................................................................................................................
................................................ Front, Rear Washer Fuse 48 ..............................................................
.......................................................................................................................................... Rear
Defogger Fuse 49 ................................................................................................................................
............................................... Antilock Brake System Motor Fuse 50 ................................................
.......................................................................................................................................................
Battery Main 2 Fuse 52 .......................................................................................................................
................................................................ Daytime Running Lamps Fuse 53 ......................................
..............................................................................................................................................................
......... Fog Lamps Fuse 54 ...................................................................................................................
......................................................... Climate Control System Blower Fuse 57 ...................................
..............................................................................................................................................................
...... Battery Main 1 Fuse 63 ................................................................................................................
......................................................................... Electric Power Steering
RELAYS - USAGE
Relay 31 ..............................................................................................................................................
......................................................... Ignition Main Relay 46 ...............................................................
.................................................................................................... Air Conditioning Compressor
Clutch Relay 47 ...................................................................................................................................
......................................................................... Powertrain Relay 51 ..................................................
..............................................................................................................................................................
.... Spare Relay 55 ...............................................................................................................................
..................................................................................... Crank Relay 56 ..............................................
..............................................................................................................................................................
........ Fan 1 Relay 58
.....................................................................................................................................................
Passenger Side Trailer Stoplamp, Turn Signal Relay 59
..........................................................................................................................................................
Driver Side Trailer Stoplamp, Turn Signal Relay 60 ............................................................................
........................................................................................................................................ Fan 3 Relay
61 .........................................................................................................................................................
........................................................... Fan 2 Relay 62 ........................................................................
.................................................................................................................................... Fuel Pump
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Compartment Fuse Block > Page 12268
Fuse: Locations Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
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Compartment Fuse Block > Page 12270
Fuse: Locations Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Compartment Fuse Block > Page 12272
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Underhood Fuse Block
Fuse: Application and ID Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood Label
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Fuse: Application and ID Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuse Block: Locations
Front of Vehicle/Engine Compartment Component Views
Front Engine Compartment Components
1 - Fuse Block - Underhood 2 - Battery 3 - Cooling Fan - Left 4 - Cooling Fan - Right
Left Front Engine Compartment Components 2 of 2
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1 - Fuse Block - Underhood 2 - Left Front Strut Tower 3 - Engine Control Module (ECM)
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Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Fuse Block: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12485
Fuse Block: Connector Views
Underhood Fuse Block
Electrical Center Identification Views
Fuse Block - Underhood X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12486
Fuse Block - Underhood X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12487
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12488
Fuse Block - Underhood X2 (Pin 1 To 41)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12489
Fuse Block - Underhood X2 (Pin 42 To C)
Fuse Block - Underhood X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12490
Instrument Panel Fuse Block
Electrical Center Identification Views
Fuse Block - Instrument Panel X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12491
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12492
Fuse Block - Instrument Panel X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12493
Fuse Block - Instrument Panel X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12494
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12495
Fuse Block - Instrument Panel X3 (Pin 1 To 38)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams >
Diagram Information and Instructions > Page 12496
Fuse Block - Instrument Panel X3 (Pin 39 To C)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and
Repair > Instrument Panel Electrical Center or Junction Block Replacement
Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement
Instrument Panel Electrical Center or Junction Block Replacement
Removal Procedure
Important: Record all preset radio stations.
1. Turn the ignition OFF. 2. Remove the screws from the battery cooling box. Remove the battery
cover. 3. Disconnect the negative battery cable. 4. Disconnect the positive battery cable. 5.
Remove the console.
6. Remove the nut holding the following fuse block connectors to the back of the I/P fuse block (4):
* The body connector (1)
* The I/P connector (2)
* The I/P connector (3)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and
Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 12499
7. Remove the bolt holding the fuse block into place. 8. Remove the ground wire (1). 9. Remove
the fuse block.
Installation Procedure
Notice: Refer to Fastener Notice.
1. Install the fuse block and attach the ground wire (1) and attach the bolt.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and
Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 12500
2. Connect the harness connectors to the back of the I/P fuse block (4).
Tighten the connectors to 4 N.m (35 lb in).
3. Install the console. 4. Connect the positive battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
5. Connect the negative battery cable.
Tighten the bolt to 17 N.m (13 lb ft).
6. Install the battery cooling box cover and install the screws.
Tighten the screws to 2 N.m (18 lb in).
7. Set the radio stations to the preset selections.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and
Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 12501
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement
Underhood Electrical Center or Junction Block Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and
Repair > Instrument Panel Electrical Center or Junction Block Replacement > Page 12502
Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket
Replacement
Underhood Electrical Center or Junction Block Bracket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair
Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12507
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12508
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12509
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12510
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12511
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical
Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12512
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 12521
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 >
Electrical - Intermittent MIL/DTC P2138/Reduced Power
Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC
P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 >
Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12527
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199
Multiple Junction Connector: Diagrams X100 - X199
X103
Inline Harness Connector End Views
X103 Left Front Wheel Speed Sensor Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Right Front Wheel Speed Sensor Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12530
X106
Inline Harness Connector End Views
X106 Body Harness to the Engine Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12531
X101
Inline Harness Connector End Views
X101 Body Harness to the Forward Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12532
X102
Inline Harness Connector End Views
X102 Body Harness to the Battery Cable Harness
X105
Inline Harness Connector End Views
X105 Engine Harness to the Fuel Injector Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12533
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to the Right Cooling Fan Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12534
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12535
Multiple Junction Connector: Diagrams X200 - X299
X204
Inline Harness Connector End Views
X204 Instrument Panel Harness to the Body Harness
X206
Inline Harness Connector End Views
X206 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12536
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12537
X206 Instrument Panel Harness To The Body Harness (Pin 1 To 19)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12538
X206 Instrument Panel Harness To The Body Harness (Pin 20 To 26)
X207
Inline Harness Connector End Views
X207 Console Harness to the Instrument Panel Harness (UUC -C69)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12539
X214
Inline Harness Connector End Views
X214 Passenger Airbag Jumper Harness to the Instrument Panel Harness
X218
Inline Harness Connector End Views
X218 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12540
X219
Inline Harness Connector End Views
X219 Body Harness to the Instrument Panel Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12541
X226
Inline Harness Connector End Views
X226 Instrument Panel Harness to the Shifter Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12542
X210
Inline Harness Connector End Views
X210 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12543
X275
Inline Harness Connector End Views
X275 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12544
X276
Inline Harness Connector End Views
X276 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12545
X277
Inline Harness Connector End Views
X277 Steering Wheel Controls Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12546
X216
Inline Harness Connector End Views
X216 Instrument Panel Harness to the HVAC Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12547
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12548
Multiple Junction Connector: Diagrams X300 - X399
X305
Inline Harness Connector End Views
X305 Console Harness to the Body Harness
X308
Inline Harness Connector End Views
X308 Body Harness to the Power Seat Harness (AG1 -KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12549
X308 Body Harness to the Driver Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12550
X309
Inline Harness Connector End Views
X309 Body Harness to the Passenger Seat Harness (-KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12551
X309 Body Harness to the Passenger Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12552
X311
Inline Harness Connector End Views
X311 Headliner Harness to the Sunshade Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12553
X312
Inline Harness Connector End Views
X312 Driver Seat Harness to the Power Seat Harness (AG1 +KA1)
X313
Inline Harness Connector End Views
X313 Passenger Presence Harness to the Passenger Seat Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12554
X314
Inline Harness Connector End Views
X314 Headliner Harness to the Sunroof Harness (CF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12555
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12556
Multiple Junction Connector: Diagrams X400 - X499
X400
Inline Harness Connector End Views
X400 Body Harness to the Chassis Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12557
X403
Inline Harness Connector End Views
X403 Body Harness to the Left Tail Lamp Harness
X404
Inline Harness Connector End Views
X404 Body Harness to the Right Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12558
X401
Inline Harness Connector End Views
X401 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12559
X405
Inline Harness Connector End Views
X405 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12560
X406
Inline Harness Connector End Views
X406 Body Harness to the Fuel Sender Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12561
X409
Inline Harness Connector End Views
X409 Body Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12562
X410
Inline Harness Connector End Views
X410 Trailer Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12563
X412
Inline Harness Connector End Views
X412 Headliner to the Instrument Panel Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12564
X414
Inline Harness Connector End Views
X414 Body to the CHMSL Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12565
X415
Inline Harness Connector End Views
X415 Headliner Harness to the Body Harness
X417
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12566
Inline Harness Connector End Views
X417 Headliner Harness to the Body Harness (U3U)
X420
Inline Harness Connector End Views
X420 Body Harness to the Left Inflatable Restraint Roof Rail Module Harness (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12567
X421
Inline Harness Connector End Views
X421 Body Harness to the Right Inflatable Restraint Roof Rail Module Harness (ASF)
X422
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12568
Inline Harness Connector End Views
X422 Headliner Harness to the Body Harness (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12569
Multiple Junction Connector: Diagrams
X103
Inline Harness Connector End Views
X103 Left Front Wheel Speed Sensor Harness to the Body Harness
X104
Inline Harness Connector End Views
X104 Right Front Wheel Speed Sensor Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12570
X106
Inline Harness Connector End Views
X106 Body Harness to the Engine Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12571
X101
Inline Harness Connector End Views
X101 Body Harness to the Forward Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12572
X102
Inline Harness Connector End Views
X102 Body Harness to the Battery Cable Harness
X105
Inline Harness Connector End Views
X105 Engine Harness to the Fuel Injector Harness (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12573
X108
Inline Harness Connector End Views
X108 Forward Lamp Harness to the Right Cooling Fan Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12574
X204
Inline Harness Connector End Views
X204 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12575
X206
Inline Harness Connector End Views
X206 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12576
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12577
X206 Instrument Panel Harness To The Body Harness (Pin 1 To 19)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12578
X206 Instrument Panel Harness To The Body Harness (Pin 20 To 26)
X207
Inline Harness Connector End Views
X207 Console Harness to the Instrument Panel Harness (UUC -C69)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12579
X214
Inline Harness Connector End Views
X214 Passenger Airbag Jumper Harness to the Instrument Panel Harness
X218
Inline Harness Connector End Views
X218 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12580
X219
Inline Harness Connector End Views
X219 Body Harness to the Instrument Panel Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12581
X226
Inline Harness Connector End Views
X226 Instrument Panel Harness to the Shifter Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12582
X210
Inline Harness Connector End Views
X210 Instrument Panel Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12583
X275
Inline Harness Connector End Views
X275 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12584
X276
Inline Harness Connector End Views
X276 Instrument Panel Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12585
X277
Inline Harness Connector End Views
X277 Steering Wheel Controls Harness to the Steering Wheel Module Coil Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12586
X216
Inline Harness Connector End Views
X216 Instrument Panel Harness to the HVAC Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12587
X305
Inline Harness Connector End Views
X305 Console Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12588
X308
Inline Harness Connector End Views
X308 Body Harness to the Power Seat Harness (AG1 -KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12589
X308 Body Harness to the Driver Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12590
X309
Inline Harness Connector End Views
X309 Body Harness to the Passenger Seat Harness (-KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12591
X309 Body Harness to the Passenger Seat Harness (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12592
X311
Inline Harness Connector End Views
X311 Headliner Harness to the Sunshade Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12593
X312
Inline Harness Connector End Views
X312 Driver Seat Harness to the Power Seat Harness (AG1 +KA1)
X313
Inline Harness Connector End Views
X313 Passenger Presence Harness to the Passenger Seat Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12594
X314
Inline Harness Connector End Views
X314 Headliner Harness to the Sunroof Harness (CF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12595
X400
Inline Harness Connector End Views
X400 Body Harness to the Chassis Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12596
X403
Inline Harness Connector End Views
X403 Body Harness to the Left Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12597
X404
Inline Harness Connector End Views
X404 Body Harness to the Right Tail Lamp Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12598
X401
Inline Harness Connector End Views
X401 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12599
X405
Inline Harness Connector End Views
X405 Liftgate Jumper to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12600
X406
Inline Harness Connector End Views
X406 Body Harness to the Fuel Sender Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12601
X409
Inline Harness Connector End Views
X409 Body Harness to the Trailer Jumper Harness (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12602
X410
Inline Harness Connector End Views
X410 Trailer Harness to the Trailer Jumper Harness (V92)
X412
Inline Harness Connector End Views
X412 Headliner to the Instrument Panel Harness (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12603
X414
Inline Harness Connector End Views
X414 Body to the CHMSL Jumper Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12604
X415
Inline Harness Connector End Views
X415 Headliner Harness to the Body Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12605
X417
Inline Harness Connector End Views
X417 Headliner Harness to the Body Harness (U3U)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12606
X420
Inline Harness Connector End Views
X420 Body Harness to the Left Inflatable Restraint Roof Rail Module Harness (ASF)
X421
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12607
Inline Harness Connector End Views
X421 Body Harness to the Right Inflatable Restraint Roof Rail Module Harness (ASF)
X422
Inline Harness Connector End Views
X422 Headliner Harness to the Body Harness (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12608
X500 - X599
Inline Harness Connector End Views
X500 Body Harness to the Left Front Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12609
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12610
X600 - X699
Inline Harness Connector End Views
X600 Body Harness to the Right Front Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12611
X700 - X799
Inline Harness Connector End Views
X700 Body Harness to the Left Rear Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12612
X800 - X899
Inline Harness Connector End Views
X800 Body Harness to the Right Rear Door Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12613
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12614
X902
Inline Harness Connector End Views
X902 Liftgate Jumper to Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12615
X906
Inline Harness Connector End Views
X906 Liftgate Jumper to Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12616
X907
Inline Harness Connector End Views
X907 License Lamp Harness to the Liftgate Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12617
X908
Inline Harness Connector End Views
X908 License Lamp Harness to the Liftgate Harness
X911
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > X100 - X199 > Page 12618
Inline Harness Connector End Views
X911 CHMSL Jumper Harness to the CHMSL Harness
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12623
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12624
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness)
Relay Replacement (Attached to Wire Harness)
Removal Procedure
1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any
connector position assurance (CPA) devices or secondary locks.
Important: Use care when removing a relay in a wiring harness when the relay is secured by
fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
Installation Procedure
1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position
assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that
originally held the relay in place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
> Page 12630
Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center)
Relay Replacement (Within an Electrical Center)
Tools Required
J 43244 Relay Puller Pliers
Removal Procedure
1. Remove the electrical center cover. 2. Locate the relay.
Important: *
Always note the orientation of the relay.
* Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
Using the J 43244 (1) position the tool on opposing corners of the relay (2).
Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of
pliers or a flat bladed tool could damage the electrical center.
3. Remove the relay (2) from the electrical center.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness)
> Page 12631
1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules
Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 12640
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 12641
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control
Modules > Page 12642
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced
Power
Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced
Power > Page 12647
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 12653
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 12654
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL
ON/DTC's Set By Various Control Modules > Page 12655
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12660
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12661
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12662
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12663
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12664
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information
For Electrical Ground Repair > Page 12665
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power
Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced
Power
TECHNICAL
Bulletin No.: 07-06-04-019D
Date: June 28, 2010
Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced
Engine Power (Repair Instrument Panel (IP) to Body Harness Connector)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years and warranty information.
Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion
System)
Condition
- Some customers may comment on an intermittent malfunction indicator lamp (MIL) being
Illuminated with a message or an indicator that displays Reduced Engine Power.
- The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP)
Sensor 1-2 Correlation set as Current or in History.
Cause
This condition may be caused by water intrusion into the instrument panel (IP) to body harness
connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a
voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value
for more than a calibrated period of time, setting P2138.
Correction
Note Aftermarket equipment can generate DTC P2138 and/or other DTCs.
1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or
low reference circuits or to any other ECM/PCM
5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI.
2. Perform the Diagnostic System Check - Vehicle.
‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any
5V reference DTCs are not set, proceed to Step 3.
3. Locate the IP to body harness connector, which may be located in and around the left hand kick
panel area or inside the IP. Depending on the
vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI.
Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped)
and windshield/cowl sealing.
4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the
leak. Refer to General Information > Water Leaks
in SI.
‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair.
5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for
Intermittent Conditions and Poor Connections in
SI.
‹› If any corrosion and/or debris is observed, repair as necessary.
6. After completing the repair, verify the proper operation of the system. Depending on the vehicle
and model year, perform the Diagnostic Repair
Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent
MIL/DTC P2138/Reduced Power > Page 12670
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the appropriate labor operation for the source of the
water leak
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair
Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair
INFORMATION
Bulletin No.: 10-08-45-001B
Date: October 25, 2010
Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with
Conductive Finish
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty
Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and
Accessories).
Electrical Ground Repair Overview
Proper electrical system function relies on secure, stable and corrosion-free electrical ground
connections. Loose, stripped, or corroded connections increase the possibility of improper system
function and loss of module communication. These conditions may also lead to unnecessary
repairs and component replacement.
In general, electrical ground connections are accomplished using one, or a combination of the
following attachment methods:
- Welded M6 stud and nut
- Welded M6 nut and bolt
- Welded M8 nut and bolt
Determine which attachment method is used and perform the appropriate or alternative repair as
described in this bulletin.
M6 Weld Stud Replacement
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in)
clearance behind the panel surface and 20 mm (0.79 in)
clearance surrounding the M6 conductive rivet stud flange.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
3. Drill a 10 mm (0.40 in) diameter hole through the panel.
4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is
visible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12676
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9.
Completely wrap the threads of the rivet stud with painters tape or equivalent.
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the ground wire terminal and conductive nut to maintain a secure, stable and
corrosion-free electrical ground.
10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet
stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12677
15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6
conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive
nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in).
19. Verify proper system operation.
M6 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive
self-threading bolt may be used to secure the ground
wire terminal.
2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged
or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the
Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N
12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading
bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt.
8. Install the M7 conductive self-threading bolt and:
Tighten Tighten to 9 Nm (80 lb in).
9. Verify proper system operation.
M6 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt
and a M6 conductive nut may be used to secure
the electrical ground wire terminal. Refer to the Parts Information section of this bulletin.
2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground
location.
10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M6 conductive nut to the bolt and:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12678
Tighten Tighten to 8 Nm (71 lb in).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8
conductive bolt and a M8 conductive nut may be
used to secure the electrical ground wire terminal. Refer to the Parts Information section of this
bulletin.
2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel
surface and 20 mm (0.79 in) clearance surrounding
the new electrical ground site.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface
surrounding the ground location and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the
area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive
bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground
location.
10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the
M8 conductive nut to the bolt and:
Tighten Tighten to 22 Nm (16 lb ft).
Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free
electrical ground.
12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 13. Verify proper system operation.
M8 Weld Nut Alternative Repair
Caution
Use only the GM-approved replacement fasteners with conductive finish for electrical ground
repair.
1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6
conductive rivet stud and a M6 conductive nut
may be used to secure the electrical ground wire terminal.
2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind
the panel surface and 20 mm (0.79 in) clearance
surrounding the M6 conductive rivet stud flange.
3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site
and allow to dry.
Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled.
4. Drill a 10 mm (0.40 in) diameter hole through the panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12679
5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is
visible.
Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of
0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any
air gaps to ensure a good ground.
6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin.
Note Use the GE-50317 rivet stud tool kit.
7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool
(2) with the groove and flare side facing the rivet
stud, then the washer and the M6 nut (3).
8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive
rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement.
10. Completely wrap the threads of the rivet stud with painters tape or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12680
Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the
installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable
and corrosion-free electrical ground.
11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and
Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective
material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet
stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet
stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric
Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet
stud.
Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is
a small motion between electrical contacts. The oxidized wear debris can accumulate at the
electrical contact points causing the electrical resistance across the connection to increase.
16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground
wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18.
Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6
conductive nut to the rivet stud and:
Tighten Tighten to 8 Nm (71 lb in)
20. Verify proper system operation.
Parts Information
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For
Electrical Ground Repair > Page 12681
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Wheel Alignment Specifications
Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications
WARRANTY ADMINISTRATION
Bulletin No.: 05-03-07-009C
Date: December 09, 2010
Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks
Supercede: This bulletin is being extensively revised to provide technicians and warranty
administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF
WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT
SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension).
Purpose
The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors'
warranty service requirements and recommendations for customer concerns related to wheel
alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel
Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty
service.
Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING
YOUR NEXT GM WHEEL ALIGNMENT SERVICE.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a
successful wheel alignment service.
1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension
and steering configurations. Vehicles
modified in any of these areas are not covered for wheel alignment warranty.
2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is
within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for
labor operations E2000 and E2020.
The following information must be documented or attached to the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the
appropriate calibration maintenance schedules.
Important If it is determined that a wheel alignment is necessary under warranty, use the proper
labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel
Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for
other component repairs is to be charged to the component that causes a wheel alignment
operation.).
The following flowchart is to help summarize the information detailed in this bulletin and should be
used whenever a wheel alignment is performed.
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Verify Original Equipment Condition of the Vehicle
- Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are
on the vehicle.
- Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have
NOT been done to the vehicle.
- Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision
damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles,
suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact.
- Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving
may show up by looking at the tires and condition of the vehicle.
- Check for other additional equipment items that may significantly affect vehicle mass such as
large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in
trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and
wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed
semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of
these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with
equipment such as the above.)
Customer Concerns, "Normal Operation" Conditions and "Mileage Policy"
Possible Concerns
The following are typical conditions that may require wheel alignment warranty service:
1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of
effort required at the steering wheel to maintain the
vehicle's straight heading."
Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle
Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull
concerns can be due to road crown or road slope, tires, wheel alignment or even in rare
circumstances a steering gear issue. Lead/pull concerns due to road crown are considered
"Normal Operation" and are NOT a warrantable condition -- the customer should be advised that
this is "Normal Operation."
Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a
level condition. If so, this is more likely a "steering wheel angle" concern because the customer is
"steering" the vehicle to obtain a "level" steering wheel.
2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined
as the steering wheel angle (clocking)
deviation from "level" while maintaining a straight heading on a typical straight road.
3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the
shoulders of tires is NOT considered unusual and
should even out with a tire rotation; if the customer is concerned about a "feathering" condition of
the tires, the customer could be advised to rotate the tires earlier than the next scheduled
mileage/maintenance interval (but no later than the next interval). Be sure to understand the
customer's driving habits as this will also heavily influence the tire wear performance; tire wear from
aggressive or abusive driving habits is NOT a warrantable condition.
Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is
"normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can
show evidence of feathering from the factory. These issues do NOT affect the overall performance
and tread life of the tire. Dealer personnel should always check the customer's maintenance
records to ensure that tire inflation pressure is being maintained to placard and that the tires are
being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be
performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below.
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Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center
Ribs
Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder
Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear
Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear
Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the
repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center
wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF,
LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life,
etc. A field product report with pictures of the tire wear condition is recommended. Refer to
Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C.
4. Other repairs that affect wheel alignment; e.g., certain component replacement such as
suspension control arm replacement, engine cradle
adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock,
steering knuckle, etc. may require a wheel alignment.
Important If other components or repairs are identified as affecting the wheel alignment, policy calls
for the wheel alignment labor time to be charged to the replaced/repaired component's labor
operation time rather than the wheel alignment labor operations.
Important Vibration type customer concerns are generally NOT due to wheel alignment except in
the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are
NOT to be performed as an investigation/correction for vibration concerns.
"Normal Operation" Conditions
Vehicle Lead/Pull Due to Road Crown or Slope:
As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope.
Be sure to verify from the customer the types of roads they are driving as they may not recognize
the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires
significant steering effort to prevent it from "climbing" the road crown there may be an issue to be
looked into further.
Important
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A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within
"Normal Operation."
Mileage Policy
The following mileage policy applies for E2020 and E2000 labor operations: Note
Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana
Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing
the vehicles.
- 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to
the tie down during shipping, the vehicle's suspension requires some time to reach normal
operating position. For this reason, new vehicles are generally NOT to be aligned until they have
accumulated at least 800 km (500 mi). A field product report should accompany any claim within
this mileage range.
- 801-12,000 km (501-7,500 mi):
- If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle
steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be
apparent early in the life of the vehicle. The following policy applies:
- Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT,
Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and
Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required
- All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above:
E2000/E2020 Claims: Dealer Service Manager Authorization Required
- 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible
for the wheel alignment expense or dealers may provide on a case-by case basis a one-time
customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component
required the use of the subject labor operations, the identified defective component labor operation
will include the appropriate labor time for a wheel alignment as an add condition to the component
repair.
Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN.
Warranty Documentation Requirements
When a wheel alignment service has been deemed necessary, the following items will need to be
clearly documented on/with the repair order:
- Customer concern in detail
- What corrected the customer concern?
- If a wheel alignment is performed:
- Consult SI for proper specifications.
- Document the "Before" AND "After" wheel alignment measurements/settings.
- Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin)
1. Document the customer concern in as much detail as possible on the repair order and in the
warranty administration system. Preferred examples:
- Steering wheel is off angle in the counterclockwise direction by approximately x degrees or
clocking position.
- Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe,
Moderate or Slight.
- RF and LF tires are wearing on the outside shoulders with severe feathering.
Important In the event of a lead/pull or steering wheel angle concern, please note the direction of
lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the
repair order and within the warranty claim verbatim.
Important In the event of a tire wear concern, please note the position on the vehicle and where the
wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder.
2. Document the technician's findings on cause and correction of the issue. Examples:
- Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees
to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees.
- Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of
+0.30 degrees to 0.00 degrees on the vehicle.
- Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees.
3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the
Repair Order or if print-out capability is not
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available, measurements may also be clearly and legibly handwritten into the Wheel Alignment
Repair Order Questionnaire attached to this bulletin.
4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of
"Before" and "After" wheel alignment measurements to
the Repair Order and retain for use by GM.
Wheel Alignment Equipment and Process
Wheel alignments must be performed with a quality machine that will give accurate results when
performing checks. "External Reference" (image-based camera technology) is preferred. Please
refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment
Requirements and Recommendations.
Requirements:
- Computerized four wheel alignment system.
- Computer capable of printing before and after alignment reports.
- Computer capable of time and date stamp printout.
- Racking system must have jacking capability
- Racking system must be capable of level to 1.6 mm (1/16 in)
- Appropriate wheel stops and safety certification
- Built-in turn plates and slip plates
- Wheel clamps capable of attaching to 20" or larger wheels
- Racking capable of accepting any GM passenger car or light duty truck
- Operator properly trained and ASE-certified (U.S. only) in wheel alignment
Recommendations:
Racking should have front and rear jacking capability.
Equipment Maintenance and Calibration:
Alignment machines must be regularly calibrated in order to give correct information. Most
manufacturers recommend the following:
- Alignment machines with "internal reference" sensors should be checked (and calibrated, if
necessary) every six months.
- Alignment machines with "external reference" (image-based camera technology) should be
checked (and calibrated, if necessary) once a year.
- Racks must be kept level to within 1.6 mm (1/16 in).
- If any instrument that is part of the alignment machine is dropped or damaged in some way,
check the calibration immediately.
Check with the manufacturer of your specific equipment for their recommended service/calibration
schedule.
Wheel Alignment Process
When performing wheel alignment measurement and/or adjustment, the following steps should be
taken:
Preliminary Steps:
1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels
and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4.
Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for
looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to
stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate
for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI).
Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the
wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the
specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads,
such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's
instructions.
Measure/Adjust:
Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify
that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date
by comparing these to the wheel alignment specifications for the appropriate model and model year
in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments,
irregular and/or premature tire wear and repeat customer concerns
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Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front wheel alignment angles.
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
If necessary, adjust the wheel alignment to vehicle specification and record the before and after
measurements. Refer to Wheel Alignment Specifications in SI.
Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only
source of GM wheel alignment specifications that is kept up-to-date throughout the year.
Test drive vehicle to ensure proper repair.
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Frame Angle Measurement (Express / Savana Only) ........
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What corrected the customer concern and was the repair verified?
Please Explain: .............
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Fastener
Tightening Specifications
Alignment: Specifications Fastener Tightening Specifications
Fastener Tightening Specifications
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Tightening Specifications > Page 12696
Alignment: Specifications Trim Height Specifications
Trim Height Specifications
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Alignment: Specifications Wheel Alignment Specifications
Wheel Alignment Specifications
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Caster Description
Alignment: Description and Operation Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
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Alignment: Description and Operation Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
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Alignment: Description and Operation Toe Description
Toe Description
Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
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Alignment: Description and Operation Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
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Alignment: Description and Operation
Caster Description
Caster Description
Caster Description
Caster is the tilting of the uppermost point of the steering axis either forward or backward, when
viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but does not affect the tire wear . Caster is
affected by the vehicle height, therefore it is important to keep the body at its designed height.
Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the front suspension moves to a more positive
caster. If the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
With too little positive caster, steering may be touchy at high speed and wheel returnability may be
diminished when coming out of a turn. If one wheel has more positive caster than the other, that
wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead
to the side with the least amount of positive caster.
Camber Description
Camber Description
Camber Description
Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at
the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical.
Camber settings influence the directional control and the tire wear.
Too much positive camber will result in premature wear on the outside of the tire and cause
excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and cause
excessive wear on the suspension parts.
Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side
with the most positive camber.
Toe Description
Toe Description
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Toe Description
Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the wheels roll parallel.
Toe also offsets the small deflections of the wheel support system that occur when the vehicle is
rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the
wheels tend to roll parallel on the road when the vehicle is moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
Setback Description
Setback Description
Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may
be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The
first clue is a caster difference from side-to-side of more than 1 degree.
Thrust Angles Description
Thrust Angles Description
Thrust Angles Description
The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action
relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the
thrust angle is geometrically aligned with the body centerline (2).
In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The
resulting deviation from the centerline is the thrust angle.
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If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be
centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel
alignment.
Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle.
Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle.
If the thrust angle is out of specification, moving the axle to body relationship will change the thrust
angle reading.
If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will
move the thrust angle towards zero degrees.
If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will
move the thrust angle towards zero degrees.
Lead/Pull Description
Lead/Pull Description
At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at
the steering wheel to maintain the vehicle's straight path.
Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal
operation.
Lead/pull is usually caused by the following factors:
* Road slope
* Variability in tire construction
* Wheel alignment (front cross caster and camber)
* Unbalanced steering gear
* Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if
equipped.
Torque Steer Description
Torque Steer Description
A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the
other direction during deceleration.
The following factors may cause torque steer to be more apparent on a particular vehicle:
* A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front
tires for differences in the brand, the construction, or the size. If the tires appear to be similar,
change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the
most significant effect on torque steer correction.
* A large difference in the right and left front tire pressure
* Left-to-right differences in the front view axle angle may cause significant steering pull in a
vehicle. The pull will be to the side with the most downward sloping axle from the differential to the
wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to
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level ground may be used as an indication of bias axle angles. The side with the higher transaxle
pan (shown on the left side of the illustration) has the most downward sloping axle angle.
Memory Steer Description
Memory Steer Description
Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned
the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in
that direction.
Wander Description
Wander Description
Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with
hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external
disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel.
Scrub Radius Description
Scrub Radius Description
Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the
tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the
SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle
to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller
the scrub radius, the better the directional stability. Installing aftermarket wheels that have
additional offset will dramatically increase the scrub radius. The newly installed wheels may cause
the centerline of the tires to move further away from the spindle. This will increase the scrub radius.
A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive
vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub
radius is not directly measurable by the conventional methods. Scrub radius is projected
geometrically by engineers during the design phase of the suspension.
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Page 12707
Alignment: Testing and Inspection
Trim Height Inspection
Trim Height Measurement
Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights
can cause the vehicle to bottom out over bumps, damage to the suspension components and
symptoms similar to wheel alignment problems. Check the trim heights when diagnosing
suspension concerns and before checking the wheel alignment.
Perform the following before measuring the trim heights:
* Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle
Certification, Tire Placard, Anti-Theft, and Service Parts ID Label .
* Check the fuel level. Add additional weight if necessary to simulate a full tank. One U.S. gallon of
gasoline weighs approximately 6.5 lbs. One liter of gasoline weights approximately 0.70 kg.
* Make sure the passenger and rear compartments are empty, except tor the spare tire.
* Make sure the vehicle is on a flat and level surface, such as an alignment rack.
* For vehicles equipped with automatic level control, ensure the system is functioning properly.
* Check that all the vehicle doors are securely closed.
* Check that the vehicle hood and rear deck lids are securely closed.
* Check for installed after market accessories or modifications that could affect trim height
measurement:
- Larger of smaller than production wheels and tires
- Lifting or lowering kits
- Wheel opening flares or ground affects
Measuring the P and R Heights
Important: The left and right P and R height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the P and R dimensions:
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure vertically
from the ground to the bottom lip of the wheel opening through the centerline of the front wheel, P
height. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your
hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8.
Re-measure the P height as in step 4.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 12708
9. The true P height is the average of the measurements taken in steps 4 and 8. Refer to Trim
Height Specifications (See:
Suspension/Specifications/Trim Height Specifications) .
10. Repeat the above steps at the rear of the vehicle for the R heights. 11. If the P and R heights
are outside of specifications, measure the Z and D heights.
Measuring the Z Height
Measuring Z Height
Important:
*
In order to obtain the proper measurement, Z will equal inner minus the outer.
* The left and right Z height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the Z height:
1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Repeat this
jouncing operation 2 more times for a total of 3 times. 5. Measure from the center of the lower ball
joint (A) to the alignment rack. 6. Measure from the center of the cradle (B) to the alignment rack. 7.
The difference between these 2 measurements is the Z height. 8. Push the front bumper of the
vehicle down about 38 mm (1.5 in). 9. Gently remove your hands and let the vehicle settle.
10. Repeat this operation 2 more times for a total of 3 times. 11. Re-measure the Z height as in
step 4. 12. The true Z height is the average of the measurements taken in steps 4 and 8. Refer to
Trim Height Specifications (See:
Suspension/Specifications/Trim Height Specifications) .
If any of these measurements are out of specifications, inspect for the following conditions:
* Worn or damage suspension components
* Collision damage
Measuring the D Height
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 12709
Measuring D Height
Important:
* In order to obtain the proper measurement, D will equal inner minus the outer.
* The left and right D height difference should be no more than 12 mm (0.47 in).
Use the following procedure to measure the D height:
1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let
the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure from the
center of the inner pivot bolt (A) to the alignment rack. 5. Measure from the center of the outer pivot
bolt (B) to the alignment rack. 6. The difference between these 2 measurements is the D height. 7.
Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 8. Gently remove your hands and let
the vehicle settle. 9. Repeat this operation 2 more times for a total of 3 times.
10. Re-measure the D height as in step 4. 11. The true D height is the average of the
measurements taken in steps 4 and 8. Refer to Trim Height Specifications (See:
Suspension/Specifications/Trim Height Specifications) .
If any of these measurements are out of specifications, inspect for the following conditions:
* Worn or damage suspension components
* Collision damage
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement
Alignment: Service and Repair Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel
Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering/Specifications) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber
Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Trim Height Inspection) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12712
Alignment: Service and Repair Front Camber Adjustment
Front Camber Adjustment
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the wheel
and tire assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
3. Remove the strut to knuckle nuts and bolts. Discard the nuts and bolts.
4. If the strut has not been previously modified, perform the following procedure:
1. Disconnect the strut from the knuckle.
Important:
* Maximum outboard adjustment-(increased negative camber) 2.0 mm of outboard elongation or to
within 11.0 mm from outboard edge of lower strut clevis bracket, whichever comes first
* Maximum inboard adjustment-(increased positive camber) 4.0 mm of inboard elongation
* If filing the strut, paint the exposed metal with primer.
2. If increasing negative camber, remove material from the outside of the lower strut hole. 3. If
decreasing negative camber, remove material from the inside of the lower strut hole.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12713
5. Loosely install new strut to knuckle nuts and bolts.
6. Adjust the camber to specifications by moving the top of the wheel in or out as necessary. Refer
to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
7. Tighten strut to knuckle nuts and bolts.
Tighten the nuts and bolts to 180 N.m (133 lb ft).
8. Install the wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12714
Alignment: Service and Repair Front Caster Adjustment
Front Caster Adjustment
The front caster is not adjustable. If the front caster angle is not within specifications, inspect for
suspension support misalignment or front suspension damage. Refer to Alignment Checking .
Replace any damaged suspension components as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12715
Alignment: Service and Repair Front Toe Adjustment
Front Toe Adjustment
1. Position and lock the steering wheel with the vehicle with the wheels in the straight forward
position.
2. Loosen both inner tie rod jam nuts.
Important: The inner tie rod must rotate freely from the boot seal surface. Do not allow the boot to
rotate.
3. Loosen the inner tie rod seal to boot surface. 4. Use a wrench on the tie rod flats to increase or
decrease the toe angle specifications. Refer to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
5. Tighten the inner tie rod jam nuts.
Tighten the jam nuts to 60 N.m (44 lb ft).
6. Inspect the toe angle to ensure proper adjustment and adjust as necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12716
Alignment: Service and Repair
Wheel Alignment Measurement
Wheel Alignment Measurement
Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical
straight road, lead/pull is the amount of effort required at the steering wheel to maintain the
vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and
Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull
Correction) in order to determine if the vehicle has a tire lead problem.
Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:
* Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire
Placard, Anti-Theft, and Service Parts ID Label and Tire Diagnosis - Irregular or Premature Wear
(See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire
Diagnosis - Irregular or Premature Wear) .
* Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications .
* Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis
(See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel
Bearings Diagnosis) .
* Inspect the ball joints and tie rod ends for looseness or wear.
* Inspect the control arms and stabilizer shaft for looseness or wear.
* Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications
(See: Steering/Specifications) .
* Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber
Testing - On Vehicle) .
* Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and
Inspection/Component Tests and General Diagnostics/Trim Height Inspection) .
* Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
* Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load
added.
Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in
the vehicle, these items should remain in the vehicle during alignment adjustments. Give
consideration also to the condition of the equipment being used for the alignment. Follow the
equipment manufacturer's instructions.
Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications (See: Specifications) .
Perform the following steps in order to measure the front and rear alignment angles:
1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front
and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment
angles and record the readings.
Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear
wheel alignment angles first in order to obtain proper front alignment angles.
4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment
Specifications (See: Specifications) .
Front Camber Adjustment
Front Camber Adjustment
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the wheel
and tire assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12717
3. Remove the strut to knuckle nuts and bolts. Discard the nuts and bolts.
4. If the strut has not been previously modified, perform the following procedure:
1. Disconnect the strut from the knuckle.
Important:
* Maximum outboard adjustment-(increased negative camber) 2.0 mm of outboard elongation or to
within 11.0 mm from outboard edge of lower strut clevis bracket, whichever comes first
* Maximum inboard adjustment-(increased positive camber) 4.0 mm of inboard elongation
* If filing the strut, paint the exposed metal with primer.
2. If increasing negative camber, remove material from the outside of the lower strut hole. 3. If
decreasing negative camber, remove material from the inside of the lower strut hole.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12718
5. Loosely install new strut to knuckle nuts and bolts.
6. Adjust the camber to specifications by moving the top of the wheel in or out as necessary. Refer
to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
7. Tighten strut to knuckle nuts and bolts.
Tighten the nuts and bolts to 180 N.m (133 lb ft).
8. Install the wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Front Caster Adjustment
Front Caster Adjustment
The front caster is not adjustable. If the front caster angle is not within specifications, inspect for
suspension support misalignment or front suspension damage. Refer to Alignment Checking .
Replace any damaged suspension components as necessary.
Front Toe Adjustment
Front Toe Adjustment
1. Position and lock the steering wheel with the vehicle with the wheels in the straight forward
position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12719
2. Loosen both inner tie rod jam nuts.
Important: The inner tie rod must rotate freely from the boot seal surface. Do not allow the boot to
rotate.
3. Loosen the inner tie rod seal to boot surface. 4. Use a wrench on the tie rod flats to increase or
decrease the toe angle specifications. Refer to Wheel Alignment Specifications (See:
Specifications) .
Notice: Refer to Fastener Notice .
5. Tighten the inner tie rod jam nuts.
Tighten the jam nuts to 60 N.m (44 lb ft).
6. Inspect the toe angle to ensure proper adjustment and adjust as necessary.
Rear Camber Adjustment
Rear Camber Adjustment
1. Loosen the upper control arm-to-frame fastener enough to allow movement.
Important: The frame of the vehicle is slotted, turning the cam nut will move the camber in to the
designated location.
2. Rotate the upper control arm-to-frame fastener in the direction necessary to the correct the
camber measurement. 3. Snug the upper control arm-to-frame fastener, do not tighten at this time.
4. Reinspect the rear camber specifications and adjust as necessary.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment Measurement > Page 12720
5. Hold the nut and tighten the upper control arm-to-frame bolt.
Tighten the bolt to 110 N.m (81 lb ft).
6. Repeat the procedure for the other rear wheel.
Rear Toe Adjustment
Rear Toe Adjustment
1. Loosen the suspension adjustment link-to-frame fastener enough to allow for movement.
Important: The frame of the vehicle is slotted, a cam nut is available for service if required.
2. Rotate the suspension adjustment link cam nut in the direction necessary to correct the toe
angle. 3. Snug the suspension adjustment link-to-frame fastener, do not tighten at this time. 4.
Reinspect the rear toe specifications and adjust as necessary.
Notice: Refer to Fastener Notice .
5. Hold the nut and tighten the link-to-frame fastener bolt.
Tighten the bolt to 110 N.m (81 lb ft).
6. Repeat the procedure for the other rear wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12731
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12732
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12733
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Recalls: > 07224A
> Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12734
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: Customer Interest Steering/Suspension - Noise/Looseness In Steering
Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12744
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In
Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 12754
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 12759
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 12760
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 12761
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming >
Page 12762
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering
Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545 > Page 12772
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
12778
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
12779
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
12780
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Steering Control Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page
12781
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12782
Steering Control Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12783
Steering Control Module: Diagrams
Component Connector End Views - Continued
Power Steering Control Module (PSCM) X1
Power Steering Control Module (PSCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12784
Power Steering Control Module (PSCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12785
Power Steering Control Module (PSCM) X4
Power Steering Control Module (PSCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12786
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 12787
Steering Control Module: Service and Repair
Electronic Power Steering Motor Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service
Bulletins > Tire Monitor System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 12811
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 12812
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 12813
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 12814
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS
System - Service And Re-Learning Sensor IDs > Page 12815
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page
12816
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors
and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page
12817
Notice: Refer to Fastener Notice .
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Wheels and
Tires/Tires/Service and Repair/Removal and
Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure
sensors. Refer to Tire Pressure Sensor Learn (Standard) (See: Wheels and Tires/Tire Monitoring
System/Service and
Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension
Front Steering Knuckle: Service and Repair Rear Suspension
Knuckle Replacement
Special Tools
J 37043 Park Brake Cable Release Tool
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
3. Disconnect the rear park brake cable from the park brake actuator. 4. Using the J 37043 ,
remove the park brake cable from the mounting bracket
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanics wire
or equivalent. Refer to Rear Brake Caliper Bracket
Replacement .
6. Remove the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement
(See: Suspension/Wheel Bearing/Service and
Repair/Rear Suspension) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12823
7. Remove the upper control arm to knuckle bolt and nut.
8. Remove the lower control arm to knuckle bolt and nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12824
9. Remove the toe link to knuckle bolt and nut.
10. Remove the 3 trailing arm to knuckle bolts. 11. Remove the knuckle from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12825
1. Install the knuckle to the lower control arm. Loosely install the bolt and nut.
2. Install the knuckle to the upper control arm. Loosely install the bolt and nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12826
3. Install the knuckle to the toe link. Loosely install the bolt and nut.
4. Install the 3 trailing arm to knuckle bolts. Loosely install the bolt and nut.
Notice: Refer to Fastener Notice .
5. Tighten the bolts and nuts in the following sequence:
* Tighten the knuckle to lower control arm bolt and nut to 160 N.m (118 lb ft).
* Tighten the knuckle to upper control arm bolt and nut to 160 N.m (118 lb ft).
* Tighten the knuckle to toe link bolt and nut to 160 N.m (118 lb ft).
* Tighten the 3 trailing arm to knuckle bolts to 110 N.m (81 lb ft).
6. Install the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement
(See: Suspension/Wheel Bearing/Service and
Repair/Rear Suspension) .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12827
brake hose is still connected. Failure to support the caliper in this manner will cause the flexible
brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in
turn may cause a brake fluid leak.
7. Remove the supporting wire and position the brake caliper and bracket assemblies back onto
the knuckles. Refer to Rear Brake Caliper Bracket
Replacement .
8. Connect the rear park brake cable through the mounting bracket and onto the park brake
actuator. 9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
10. Lower the vehicle. 11. Perform a vehicle wheel alignment. Refer to Wheel Alignment
Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement
).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12828
Front Steering Knuckle: Service and Repair Front Suspension
Steering Knuckle Replacement
Special Tools
J-42188-B Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) . 3. Remove the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub
Replacement (See: Suspension/Wheel Bearing/Service and
Repair/Front Suspension) .
Important: Do not allow the stabilizer link ball stud to rotate while removing the link nut.
4. Remove the nut and separate the stabilizer link from the strut assembly. 5. Loosen the steering
knuckle to strut bolts and nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12829
6. Remove and discard the lower ball joint cotter pin. 7. Loosen the ball stud nut, until level with the
top of the ball stud. 8. Using the J-42188-B , separate the lower ball joint from the steering knuckle.
9. Remove the lower ball joint nut and separate from the knuckle.
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
10. Remove the outer tie rod end from the knuckle. Refer to Rack and Pinion Outer Tie Rod End
Replacement (See: Tie Rod/Tie Rod End/Service
and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12830
11. Remove the steering knuckle to strut bolts and nuts. 12. Remove the steering knuckle from the
vehicle.
Installation Procedure
1. Position the steering knuckle to strut assembly.
2. Loosely install the strut to steering knuckle bolts and nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12831
3. Position the lower ball joint stud into the steering knuckle.
Notice: Refer to Fastener Notice .
4. Install the ball stud nut.
Tighten the nut to 40 N.m (30 lb ft) .
5. Tighten the strut to steering knuckle bolts and nuts.
Tighten the bolts and nuts to 180 N.m (133 lb ft).
Important: Do not loosen the castle nut for cotter pin installation.
6. Tighten the castle nut enough to allow for cotter pin installation.
Important: The cotter pin must not contact the wheel speed sensor or drive axle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Rear Suspension > Page 12832
7. Install a new cotter pin. 8. Install the outer tie rod end to the knuckle. Refer to Rack and Pinion
Outer Tie Rod End Replacement (See: Tie Rod/Tie Rod End/Service and
Repair) .
Important: Do not allow the stabilizer link ball stud to rotate while installing the link nut.
9. Position the stabilizer shaft link to the strut assembly and install the nut.
Tighten the nut to 65 N.m (48 lb ft).
10. Install the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub Replacement
(See: Suspension/Wheel Bearing/Service and
Repair/Front Suspension) .
11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) . 12. Lower the vehicle. 13. Perform a wheel alignment. Refer to Wheel
Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Power Steering System Bleeding
Important: *
Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for
fluid specifications. Refer to Fluid and Lubricant Recommendations .
* Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not
touch any other part of the vehicle.
* Loose connections may not leak, but could allow air into the steering system. Verify that all hose
connections are tight.
Important: Power steering fluid level must be maintained throughout bleed procedure.
1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark
on cap stick fluid level indicator.
Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost
accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will
discharge the hydro-boost accumulator.
2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following
procedure:
1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF.
3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the
Vehicle . 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times.
Vehicles equipped with hydro-boost systems or longer length power steering hoses may require
turns up to 15 to 20 stop to stops.
5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power
Steering Fluid (See: Service and
Repair/Checking and Adding Power Steering Fluid) .
6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid
aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid >
Component Information > Service Precautions
Power Steering Fluid: Service Precautions
Using Proper Power Steering Fluid Notice
Notice: When adding fluid or making a complete fluid change, always use the proper power
steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair
Power Steering Fluid Reservoir: Service and Repair
Remote Power Steering Fluid Reservoir Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair > Page 12843
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service Precautions
Power Steering Line/Hose: Service Precautions
Power Steering Hose Disconnected Notice
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected.
When disconnected, plug or cap all openings of components. Failure to do so could result in
contamination or loss of power steering fluid and damage to the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement
Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Outlet Hose
Replacement
Power Steering Fluid Reservoir Outlet Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 2.
Remove as much power steering fluid from the remote power steering fluid reservoir as possible. 3.
Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement . 4. Place
drain pans under the vehicle as needed.
5. Compress the power steering reservoir outlet hose clamp (1) and disconnect the power steering
reservoir outlet hose (2) from the remote power
steering fluid reservoir.
6. Compress the power steering reservoir outlet hose clamp (1) and disconnect the power steering
reservoir outlet hose (2) from the power steering
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12849
pump.
7. Remove the power steering reservoir outlet hose.
Installation Procedure
1. Position the power steering reservoir outlet hose to the vehicle.
2. Compress the power steering reservoir outlet hose clamp (1) and connect the power steering
reservoir outlet hose (2) to the power steering pump.
3. Compress the power steering reservoir outlet hose clamp (1) and connect the power steering
reservoir outlet hose (2) to the remote power steering
fluid reservoir.
4. Clean any excess power steering fluid from the vehicle and remove the drain pans. 5. Install the
right side engine splash shield. Refer to Engine Splash Shield Replacement . 6. Install the fuel
injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 7. Fill and bleed the power
steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service
and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12850
Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement
Power Steering Cooler Pipe/Hose Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement . 2.
Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement . 3. Remove as
much power steering fluid from the remote power steering fluid reservoir as possible. 4. Remove
the front tire/wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels
and Tires/Service and Repair) . 5. Remove the left side engine splash shield. Refer to Engine
Splash Shield Replacement . 6. Place drain pans under the vehicle as needed.
7. Compress the power steering cooler pipe clamp (1) and disconnect the power steering cooler
pipe (2) from the remote power steering fluid
reservoir.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12851
8. Disconnect the power steering cooler pipe fitting (1) from the power steering gear. 9. Unclip all
power steering cooler pipe routing brackets.
10. Remove the power steering cooler pipe from the vehicle.
Installation Procedure
1. Position the power steering cooler pipe to the vehicle. 2. Reconnect all power steering cooler
pipe routing brackets to the vehicle.
Notice: Refer to Fastener Notice .
3. Connect the power steering cooler pipe fitting (1) to the power steering gear.
Tighten to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12852
4. Compress the power steering cooler pipe clamp (1) and connect the power steering cooler pipe
(2) to the remote power steering fluid reservoir. 5. Clean any excess power steering fluid from the
vehicle and remove the drain pans. 6. Install the left side engine splash shield. Refer to Engine
Splash Shield Replacement . 7. Install the front tire/wheel assemblies. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair) . 8. Install the air cleaner
outlet duct. Refer to Air Cleaner Outlet Duct Replacement . 9. Install the fuel injector sight shield.
Refer to Fuel Injector Sight Shield Replacement .
10. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See:
Power Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12853
Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement
Power Steering Gear Inlet Pipe/Hose Replacement
Removal Procedure
1. Remove the front tire/wheel assemblies. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) . 2. Place drain pans under the vehicle as needed. 3.
Remove as much fluid from the remote power steering fluid reservoir as possible.
4. Disconnect the power steering gear inlet hose fitting (1) from the power steering pump.
5. Disconnect the power steering gear inlet hose fitting (1) from the steering gear. 6. Remove the
power steering gear inlet hose from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12854
Installation Procedure
1. Position the steering gear inlet hose to the vehicle.
Notice: Refer to Fastener Notice .
Important: Hand tighten the power steering gear inlet hose fittings before finalizing the torques.
2. Connect the power steering gear inlet hose fitting (1) to the steering gear.
Tighten the fitting to 25 N.m (18 lb ft).
3. Connect the power steering gear inlet hose fitting (1) to the power steering pump.
Tighten the fitting to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Power Steering Fluid Reservoir Outlet Hose Replacement > Page 12855
4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the front tire/wheel
assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) . 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding
(See: Power Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor >
Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips
Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement
Tips
INFORMATION
Bulletin No.: 06-02-32-013B
Date: August 07, 2009
Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is
Necessary
Models:
1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years and update the information. Please
discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering).
A recently completed analysis of returned power steering (PS) pumps that had been replaced for
noise, no power assist, no or low pressure and leaking conditions has indicated a high number of
"No Trouble Found" results.
Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering
concern, the steering system analyzer should be utilized to assist the technician in a successful
diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer.
In addition, extensive warranty analysis has shown that the following situations are all significant
root causes of PS pump failures:
- Improper pulley installation
- Re-using the O-rings
- Using fluid other than the OE-specified steering fluid
- Failure to flush the PS system
In order to help improve customer satisfaction and reduce comebacks, GM recommends the
following tips for replacing a PS pump:
1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which
could cause the pressure relief valve to stop
functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will
result in pump failure.
2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical,
distorting the pulley may damage bearings on the
new PS pump.
Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts
Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for
the vehicle.
3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must
be lubricated with OE-specific PS fluid prior to
installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT
covering the pressure bypass hole.
4. Bleed the PS system according to the procedures/recommendations in SI.
Following these procedures and using the correct tools and fluids should help ensure that the new
PS pump operates properly. Skipping steps may cost you time and trouble later.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor >
Component Information > Technical Service Bulletins > Page 12860
Power Steering Motor: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor >
Component Information > Technical Service Bulletins > Page 12861
Power Steering Motor: Service and Repair
Power Steering Assist Motor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Specifications
Power Steering Pump: Specifications
Power Steering Pump Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Service and Repair > Power Steering Pump Pulley Replacement
Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement
Power Steering Pump Pulley Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Service and Repair > Power Steering Pump Pulley Replacement > Page 12867
Power Steering Pump: Service and Repair Power Steering Pump Replacement
Power Steering Pump Replacement
Removal Procedure
Important: Do not remove the drive belt from the vehicle entirely. Only slip it off the power steering
pump and set it aside in the engine compartment.
1. Remove the drive belt. Refer to Drive Belt Replacement . 2. Remove as much power steering
fluid from the remote power steering fluid reservoir as possible. 3. Remove the right side engine
splash shield. Refer to Engine Splash Shield Replacement . 4. Place drain pans under the vehicle
as needed.
5. Compress the power steering reservoir outlet hose clamp (1) and disconnect the power steering
reservoir outlet hose (2) from the power steering
pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Service and Repair > Power Steering Pump Pulley Replacement > Page 12868
6. Disconnect the power steering gear inlet hose (1) from the power steering pump.
7. Remove the power steering pump bolts (1). 8. Remove the power steering pump through the
right wheelhouse area. 9. Transfer the power steering pump pulley if needed. Refer to Power
Steering Pump Pulley Replacement (See: ) .
Installation Procedure
1. Position the power steering pump to the vehicle through the right wheelhouse area.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Service and Repair > Power Steering Pump Pulley Replacement > Page 12869
2. Install the power steering pump bolts (1).
Tighten the bolts to 50 N.m (37 lb ft).
3. Connect the power steering gear inlet hose (1) to the power steering pump.
Tighten the fitting to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump >
Component Information > Service and Repair > Power Steering Pump Pulley Replacement > Page 12870
4. Compress the power steering reservoir outlet hose clamp (1) and connect the power steering
reservoir outlet hose (2) to the power steering pump. 5. Install the right side engine splash shield.
Refer to Engine Splash Shield Replacement . 6. Clean any excess power steering fluid from the
vehicle and remove the drain pans. 7. Install the drive belt. Refer to Drive Belt Replacement . 8. Fill
and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power
Steering Bleeding/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign - ESC/Steering Module
Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign - ESC/Steering Module
Reprogramming > Page 12879
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign - ESC/Steering Module
Reprogramming > Page 12880
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign - ESC/Steering Module
Reprogramming > Page 12881
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign - ESC/Steering Module
Reprogramming > Page 12882
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 08-02-35-003A > Jun > 09 >
Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: Customer Interest Steering/Suspension - Noise/Looseness In Steering
Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep > 07 > Brakes/Steering DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep > 07 > Brakes/Steering DTC's C0252/C0460/C056E/C0460/C0545 > Page 12892
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12902
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12907
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12908
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12909
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12910
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12920
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: > 07224A >
Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: > 07224A >
Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12926
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: > 07224A >
Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12927
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: > 07224A >
Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12928
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: > 07224A >
Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12929
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12930
Steering Control Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12931
Steering Control Module: Diagrams
Component Connector End Views - Continued
Power Steering Control Module (PSCM) X1
Power Steering Control Module (PSCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12932
Power Steering Control Module (PSCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12933
Power Steering Control Module (PSCM) X4
Power Steering Control Module (PSCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12934
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module >
Component Information > Technical Service Bulletins > Page 12935
Steering Control Module: Service and Repair
Electronic Power Steering Motor Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign ESC/Steering Module Reprogramming > Page 12945
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign ESC/Steering Module Reprogramming > Page 12946
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign ESC/Steering Module Reprogramming > Page 12947
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Recalls: > 07224A > Sep > 07 > Campaign ESC/Steering Module Reprogramming > Page 12948
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-02-35-003A > Jun > 09 >
Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: Customer Interest Steering/Suspension - Noise/Looseness In Steering
Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep > 07 >
Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: Customer Interest Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-009 > Sep > 07 >
Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12958
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12968
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12973
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12974
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12975
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Control
Module: > 07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12976
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Steering Control Module: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545
Steering Control Module: All Technical Service Bulletins Brakes/Steering - DTC's
C0252/C0460/C056E/C0460/C0545
Bulletin No.: 07-02-32-009
Date: September 28, 2007
INFORMATION
Subject: Information on Electronic Brake Control Module Set DTCs C0252/C0460 and Power
Steering Control Module Set DTCs C056E/C0460/C0545
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
If any of the following DTCs are found (current or history), the following procedure should be
performed before any components are replaced.
C0252 4A
C0460 71
C0460 4B
C0460 5A
C0460 42
C056E 4B (history only)
C0545 00 (history only)
Make sure the Tech 2(R) is updated with version 27.010 or later.
Reprogram the electronic brake control module (EBCM) software with the latest version.
Reprogram the power steering control module (PSCM) software with the latest version.
After the software has been updated, perform the following checks using the Tech 2(R):
Verify under the diagnostic menu that the STEERING WHEEL ANGLE reads zero when the wheels
are pointed straight ahead.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE SENSOR CALIBRATION
STATUS reads calibrated.
Verify under the diagnostic menu that the STEERING WHEEL ANGLE VALIDITY reads valid.
If any of the above checks are incorrect, perform the following procedure using the Tech 2(R):
Clear all the codes.
Perform the "Steering Pos./Torque Sensor Calibration" in the power steering control module.
During the calibration procedure steering assist will not function. Raising the vehicle off the ground
will reduce the steering loads and make it easier to perform the procedure.
Perform the "Steering Pos. Sensor Calibration" in the electronic brake control module.
Verify that there are no DTCs.
Test drive the vehicle.
The "SERVICE STABILITRAK" message may stay on after the codes have been cleared. It may be
necessary to drive the vehicle before the message turns off. This allows the EBCM to verify that no
malfunctions exist before turning off the message.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07-02-32-009 > Sep > 07 > Brakes/Steering - DTC's C0252/C0460/C056E/C0460/C0545 > Page 12986
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming
Technical Service Bulletin # 07224A Date: 070911
Campaign - ESC/Steering Module Reprogramming
Subject: Customer Satisfaction - Electronic Stability Control (ESC) Disabled without Warning Reprogram Computer Module # 07224A - (09/11/2007)
Models: 2007-2008 Chevrolet Equinox Equipped with a 3.4L Engine (RPO LNJ) 2007-2008 Pontiac
Torrent Equipped with a 3.4L Engine (RPO LNJ) 2008 Saturn VUE Equipped with a 2.4L Engine
(RPO LE5)
THE LABOR TIME IN THIS BULLETIN HAS BEEN REVISED. SOME VEHICLES WILL REQUIRE
POWER STEERING CONTROL MODULE PROGRAMMING IN ADDITION TO THE EBCM
PROGRAMMING. TIS2WEB WILL INSTRUCT THE TECHNICIAN IF THIS ADDITIONAL
PROGRAMMING IS REQUIRED. PLEASE DISCARD ALL COPIES OF BULLETIN 07224,
ISSUED SEPTEMBER 2007.
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2008.
Condition
Certain 2007-2008 model year Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 model year Saturn VUE vehicles equipped with a 2.4L engine
(RPO LE5) may have a condition where the Electronic Stability Control (ESC) becomes disabled
without the illumination of the warning light or DIC message. This condition can occur when the
driver leaves the ignition key in the accessory position for more than 2 seconds before starting the
vehicle. The system will reset when the vehicle is turned off but may occur again if the condition is
repeated.
Correction
Dealers/retailers are to reprogram the electronic brake control module (EBCM).
Vehicles Involved
Involved are certain 2007-2008 Chevrolet Equinox and Pontiac Torrent vehicles equipped with a
3.4L engine (RPO LNJ); and 2008 Saturn VUE vehicles equipped with a 2.4L engine (RPO LE5)
and built within the VIN breakpoints shown.
IMPORTANT:
Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s)
below. Not all vehicles within the above breakpoints may be involved.
-- GM dealers and Canadian Saturn/Saab retailers should use GMVIS.
-- Saturn US retailers should use AS400 system.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided through the applicable system listed below. Dealers/retailers will not have a report
available if they have no involved vehicles currently assigned.
-- US GM dealers - GM DealerWorld Recall Information
-- Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports
-- US Saturn retailers - Facility VIN List (included with bulletin in GM DealerWorld)
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12992
data for any purpose other than follow-up necessary to complete this program is a violation of law
in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the
follow-up necessary to complete this program.
Parts Information
No parts are required for this program.
Service Procedure
Tech 2 Legacy or J2534 Pass-Thru Programming Method for the EBCM
Important:
If Tech 2 Legacy or J2534 Pass-Thru programming fails, call Techline Customer Support Center
(TCSC). A "Candi" module is necessary.
Calibration Information
CALIBRATION INFORMATION Do not attempt to order the calibration number from GMSPO. The
calibration numbers required for this service procedure are programmed into control modules via a
Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS 2 Web version
9.0 for 2007 (available on 09/03/07). If you cannot access the calibration, call the Techline
Customer Support Center at 1-800-828-6860 (English) or 1-800-503-3222 (French) and it will be
provided.
NOTICE:
Before reprogramming, please check the battery condition to prevent a reprogramming error of any
of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during
reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional
battery. Be sure to turn off or disable any system that may put a load on the battery, such as
automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air
conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control
module damage may occur if battery voltage guidelines are not observed.
The ignition switch must be in the proper position. The Service Programming System (SPS)
application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position
of the ignition switch during the programming procedure, unless instructed to do so.
Make certain all tool connections are secure, including the following components and circuits:
^ The RS-232 communication cable port
^ The connection at the data link connector (DLC)
^ The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure
that all control module and DLC connections are secure and the TIS terminal operating software is
up to date.
1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a
charge during programming. Use an additional jump battery if necessary. Only use approved
Midtronics charger or Jumper Packs, etc. to maintain proper battery voltage during programming.
2. Reprogram the electronic brake control module (EBCM). Refer to SI and Service Programming
System (SPS) documentation for EBCM programming instructions, if required.
3. Saturn Only: If the vehicle is involved in customer satisfaction program 07232 and the repair has
not been performed, perform the repair at this time.
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
GM Dealers should refer to the General Motors Service Policies and Procedures Manual for
Courtesy Transportation guidelines. Saturn US retailers should refer to GM messenger bulletins
SAG20060292/SAG20060295 for Courtesy Transportation guidelines. Saturn Canada retailers
should refer to applicable Home Office letter on this subject.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12993
Claim Information - GM and Saturn Canada Only
Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim
Submission.
Claim Information - Saturn US Only
Customer Notification - US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer/Retailer Program Responsibility
All unsold new vehicles in dealers/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through September 30, 2008.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your
use in contacting customers. Program follow-up cards should not be used for this purpose, since
the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through September 30, 2008, you must take the steps necessary to
be sure the program correction has been made before selling or releasing the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12994
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Control Module: >
07224A > Sep > 07 > Campaign - ESC/Steering Module Reprogramming > Page 12995
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 12996
Steering Control Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 12997
Steering Control Module: Diagrams
Component Connector End Views - Continued
Power Steering Control Module (PSCM) X1
Power Steering Control Module (PSCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 12998
Power Steering Control Module (PSCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 12999
Power Steering Control Module (PSCM) X4
Power Steering Control Module (PSCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 13000
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Technical Service Bulletins > Page 13001
Steering Control Module: Service and Repair
Electronic Power Steering Motor Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming
> System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming
> System Information > Service and Repair > Page 13013
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle
Steering Gear: Service and Repair Steering Gear Boot Replacement - Off Vehicle
Steering Gear Boot Replacement - Off Vehicle
Special Tools
J 22610 Keystone Clamp Pliers
Removal Procedure
1. Remove the rack and pinion outer tie rod ends. Refer to Rack and Pinion Outer Tie Rod End
Replacement (See: Tie Rod/Tie Rod End/Service
and Repair) .
2. Remove the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) . 3. Completely remove the steering gear inner tie rod nuts.
4. Remove the steering gear boot clamp (1) from the steering gear boot.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13018
5. Cut, remove, and discard the steering gear boot clamp (1).
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
6. Remove the steering gear boot.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13019
7. Clean the steering gear inner tie rod and steering gear boot contact areas of any grease and
debris.
Installation Procedure
1. Apply approximately 3/4 of the supplied grease packet into the small end of the steering gear
boot cavity. Apply the remainder of the grease on the
shaft where the small end of the steering gear boot meets the shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13020
Important: Ensure the large end of the steering gear boot is firmly seated in the steering gear
housing groove.
2. Install the steering gear boot with the large clamp loosely attached but not crimped.
3. Use pliers J 22610 to crimp the steering gear boot clamp.
Important: Ensure the small end of the steering gear boot is firmly seated in the steering gear inner
tie rod end groove.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13021
4. Install the steering gear boot clamp (1).
5. Install the steering gear inner tie rod nuts approximately 174 mm (6.85 in) from the steering gear
boot clamp. 6. Install the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering
Gear Replacement (HPS) (See: ) . 7. Install the rack and pinion outer tie rod ends. Refer to Rack
and Pinion Outer Tie Rod End Replacement (See: Tie Rod/Tie Rod End/Service and
Repair) .
8. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power
Steering/Power Steering Bleeding/Service and
Repair) .
9. Check the front wheel alignment and adjust as necessary. Refer to Wheel Alignment
Measurement (See: Alignment/Service and Repair/Wheel
Alignment Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13022
Steering Gear: Service and Repair Steering Gear Boot Replacement - On Vehicle
Steering Gear Boot Replacement - On Vehicle
Tools Required
J 22610 Keystone Clamp Pliers
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire
assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
3. Remove the outer tie rod. Refer to Rack and Pinion Outer Tie Rod End Replacement (See: Tie
Rod/Tie Rod End/Service and Repair) . 4. Remove the jam nut.
5. Remove the spring from the boot, outer end. 6. Cut and remove the crimp clamp, inner end.
Discard the clamp.
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13023
7. Unseat the boot from the steering gear and remove.
8. Clean the inner tie rod and boot contact area of grease and debris.
Installation Procedure
Important: The inner tie rod must be free of debris and moisture. The boot sealing ares must be
clean and dry.
1. Apply approximately 3/4 of the supplied grease packet into the small end of the boot cavity.
Apply the remainder of the grease on the shaft where
the small end of the boot meats the shaft.
Important: Ensure the large end of the boot is firmly seated in the gear housing groove.
2. Install the boot with the large clamp loosely attached, not crimped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13024
3. Using the J 22610 , crimp the large clamp.
Important: Ensure the small end of the boot is firmly seated in the inner tie rod end groove.
4. Install the spring clamp to the small end of the boot.
5. Install the jam nut approximately 174 mm (6.85 in) from the boot clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13025
6. Install the outer tie rod. Refer to Rack and Pinion Outer Tie Rod End Replacement (See: Tie
Rod/Tie Rod End/Service and Repair) . 7. Install the tire assembly. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair) . 8. Check the front wheel
alignment and align as necessary. Refer to Wheel Alignment Measurement (See:
Alignment/Service and Repair/Wheel
Alignment Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13026
Steering Gear: Service and Repair Steering Gear Cylinder Pipe Assembly and Seals Replacement
- Off Vehicle
Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle
Removal Procedure
1. Remove the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) .
2. Disconnect the steering gear cylinder pipe fittings (2) from the steering gear housing and remove
the steering gear cylinder pipe (1). Remove and
discard the steering gear cylinder pipe seals.
3. Disconnect the steering gear cylinder pipe fittings (2) from the steering gear housing and remove
the steering gear cylinder pipe (1). Remove and
discard the steering gear cylinder pipe seals.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13027
1. Inspect the steering gear cylinder pipes for the following items, replace as necessary:
* Cracks
* Dents
* Damage to the threads
2. Lubricate and install the new steering gear cylinder pipe seals onto the steering gear cylinder
pipes.
3. Position the steering gear cylinder pipe (1) to the steering gear. Loosely install the steering gear
cylinder pipe fittings (2).
4. Position the steering gear cylinder pipe (1) to the steering gear. Loosely install the steering gear
cylinder pipe fittings (2).
Notice: Refer to Fastener Notice .
5. Tighten the steering gear cylinder pipe fittings
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13028
Tighten the fittings to 25 N.m(18 lb ft).
6. Install the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13029
Steering Gear: Service and Repair Steering Gear Inner Tie Rod Replacement - Off Vehicle
Steering Gear Inner Tie Rod Replacement - Off Vehicle
Disassembly Procedure
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
1. Remove the steering gear boot. Refer to Steering Gear Boot Replacement - Off Vehicle (See: ) .
2. Place the steering gear in a vise.
Notice: Do not change the steering gear preload adjustment before moving the inner tie rod from
the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod
could result in damage to the pinion and the steering gear.
3. Bend the tabs to release the retaining washer (1).
Notice: Refer to Pipe Wrench Positioning Notice .
4. Place a pipe wrench on the rack next to the steering gear inner tie rod housing (2). 5. Place a
wrench on the flats of the steering gear inner tie rod housing (2). 6. Rotate the steering gear inner
tie rod housing (2) counterclockwise while holding the steering gear rack stationary until the
steering gear inner tie
rod separates from the steering gear rack.
7. Remove and discard the retaining washer (1).
Assembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13030
1. Position the NEW retaining washer (1). 2. Attach the steering gear inner tie rod onto the steering
gear rack.
Notice: Refer to Pipe Wrench Positioning Notice .
3. Place a pipe wrench on the steering gear rack next to the steering gear inner tie rod housing (2).
Notice: Refer to Fastener Notice .
4. Place a torque wrench and OTC 09922-10010-01 Inner Tie Rod Wrench on the flats of the
steering gear inner tie rod housing (2).
Tighten to 78 N.m (58 lb ft).
5. Bend the tabs over on the retaining washer (1) to secure it. 6. Install the steering gear boot.
Refer to Steering Gear Boot Replacement - Off Vehicle (See: ) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13031
Steering Gear: Service and Repair
Steering Gear Boot Replacement - Off Vehicle
Steering Gear Boot Replacement - Off Vehicle
Special Tools
J 22610 Keystone Clamp Pliers
Removal Procedure
1. Remove the rack and pinion outer tie rod ends. Refer to Rack and Pinion Outer Tie Rod End
Replacement (See: Tie Rod/Tie Rod End/Service
and Repair) .
2. Remove the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) . 3. Completely remove the steering gear inner tie rod nuts.
4. Remove the steering gear boot clamp (1) from the steering gear boot.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13032
5. Cut, remove, and discard the steering gear boot clamp (1).
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
6. Remove the steering gear boot.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13033
7. Clean the steering gear inner tie rod and steering gear boot contact areas of any grease and
debris.
Installation Procedure
1. Apply approximately 3/4 of the supplied grease packet into the small end of the steering gear
boot cavity. Apply the remainder of the grease on the
shaft where the small end of the steering gear boot meets the shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13034
Important: Ensure the large end of the steering gear boot is firmly seated in the steering gear
housing groove.
2. Install the steering gear boot with the large clamp loosely attached but not crimped.
3. Use pliers J 22610 to crimp the steering gear boot clamp.
Important: Ensure the small end of the steering gear boot is firmly seated in the steering gear inner
tie rod end groove.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13035
4. Install the steering gear boot clamp (1).
5. Install the steering gear inner tie rod nuts approximately 174 mm (6.85 in) from the steering gear
boot clamp. 6. Install the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering
Gear Replacement (HPS) (See: ) . 7. Install the rack and pinion outer tie rod ends. Refer to Rack
and Pinion Outer Tie Rod End Replacement (See: Tie Rod/Tie Rod End/Service and
Repair) .
8. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power
Steering/Power Steering Bleeding/Service and
Repair) .
9. Check the front wheel alignment and adjust as necessary. Refer to Wheel Alignment
Measurement (See: Alignment/Service and Repair/Wheel
Alignment Measurement) .
Steering Gear Boot Replacement - On Vehicle
Steering Gear Boot Replacement - On Vehicle
Tools Required
J 22610 Keystone Clamp Pliers
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire
assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13036
3. Remove the outer tie rod. Refer to Rack and Pinion Outer Tie Rod End Replacement (See: Tie
Rod/Tie Rod End/Service and Repair) . 4. Remove the jam nut.
5. Remove the spring from the boot, outer end. 6. Cut and remove the crimp clamp, inner end.
Discard the clamp.
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
7. Unseat the boot from the steering gear and remove.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13037
8. Clean the inner tie rod and boot contact area of grease and debris.
Installation Procedure
Important: The inner tie rod must be free of debris and moisture. The boot sealing ares must be
clean and dry.
1. Apply approximately 3/4 of the supplied grease packet into the small end of the boot cavity.
Apply the remainder of the grease on the shaft where
the small end of the boot meats the shaft.
Important: Ensure the large end of the boot is firmly seated in the gear housing groove.
2. Install the boot with the large clamp loosely attached, not crimped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13038
3. Using the J 22610 , crimp the large clamp.
Important: Ensure the small end of the boot is firmly seated in the inner tie rod end groove.
4. Install the spring clamp to the small end of the boot.
5. Install the jam nut approximately 174 mm (6.85 in) from the boot clamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13039
6. Install the outer tie rod. Refer to Rack and Pinion Outer Tie Rod End Replacement (See: Tie
Rod/Tie Rod End/Service and Repair) . 7. Install the tire assembly. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair) . 8. Check the front wheel
alignment and align as necessary. Refer to Wheel Alignment Measurement (See:
Alignment/Service and Repair/Wheel
Alignment Measurement) .
Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle
Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle
Removal Procedure
1. Remove the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) .
2. Disconnect the steering gear cylinder pipe fittings (2) from the steering gear housing and remove
the steering gear cylinder pipe (1). Remove and
discard the steering gear cylinder pipe seals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13040
3. Disconnect the steering gear cylinder pipe fittings (2) from the steering gear housing and remove
the steering gear cylinder pipe (1). Remove and
discard the steering gear cylinder pipe seals.
Installation Procedure
1. Inspect the steering gear cylinder pipes for the following items, replace as necessary:
* Cracks
* Dents
* Damage to the threads
2. Lubricate and install the new steering gear cylinder pipe seals onto the steering gear cylinder
pipes.
3. Position the steering gear cylinder pipe (1) to the steering gear. Loosely install the steering gear
cylinder pipe fittings (2).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13041
4. Position the steering gear cylinder pipe (1) to the steering gear. Loosely install the steering gear
cylinder pipe fittings (2).
Notice: Refer to Fastener Notice .
5. Tighten the steering gear cylinder pipe fittings
Tighten the fittings to 25 N.m(18 lb ft).
6. Install the steering gear. Refer to Steering Gear Replacement (EPS) (See: )Steering Gear
Replacement (HPS) (See: ) .
Steering Gear Inner Tie Rod Replacement - Off Vehicle
Steering Gear Inner Tie Rod Replacement - Off Vehicle
Disassembly Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13042
Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or
contamination. If none is evident, continue with the repair. If corrosion or contamination is evident,
replace the steering gear.
1. Remove the steering gear boot. Refer to Steering Gear Boot Replacement - Off Vehicle (See: ) .
2. Place the steering gear in a vise.
Notice: Do not change the steering gear preload adjustment before moving the inner tie rod from
the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod
could result in damage to the pinion and the steering gear.
3. Bend the tabs to release the retaining washer (1).
Notice: Refer to Pipe Wrench Positioning Notice .
4. Place a pipe wrench on the rack next to the steering gear inner tie rod housing (2). 5. Place a
wrench on the flats of the steering gear inner tie rod housing (2). 6. Rotate the steering gear inner
tie rod housing (2) counterclockwise while holding the steering gear rack stationary until the
steering gear inner tie
rod separates from the steering gear rack.
7. Remove and discard the retaining washer (1).
Assembly Procedure
1. Position the NEW retaining washer (1). 2. Attach the steering gear inner tie rod onto the steering
gear rack.
Notice: Refer to Pipe Wrench Positioning Notice .
3. Place a pipe wrench on the steering gear rack next to the steering gear inner tie rod housing (2).
Notice: Refer to Fastener Notice .
4. Place a torque wrench and OTC 09922-10010-01 Inner Tie Rod Wrench on the flats of the
steering gear inner tie rod housing (2).
Tighten to 78 N.m (58 lb ft).
5. Bend the tabs over on the retaining washer (1) to secure it. 6. Install the steering gear boot.
Refer to Steering Gear Boot Replacement - Off Vehicle (See: ) .
Steering Gear Replacement (Electronic Power Steering)
Steering Gear Replacement (EPS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13043
Special Tools
J 24319-B Steering Linkage and Tie Rod Puller
Removal Procedure
Notice: Secure the steering wheel utilizing a strap to prevent rotation. Locking of the steering
column will prevent damage and a possible malfunction of the SIR system. The steering wheel
must be secured in position before disconnecting the following components:
* The steering column
* The intermediate shaft
* The steering gear
After disconnecting these components, do not move the front tires and wheels. Failure to follow
these procedures may cause improper alignment of some components during installation and
result in possible damage to the SIR coil.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the front
tires. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
3. Remove both outer tie rod to steering knuckle nuts. Discard the nuts.
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13044
Important: Hold the ball stud to prevent turning during removal of the nut.
4. Using the J 24319-B , separate the tie rods from the steering knuckles.
5. Rotate the intermediate steering shaft in order to gain access to the intermediate shaft pinch
bolt. 6. Remove the intermediate to steering gear pinch bolt. Discard the bolt. 7. Disconnect the
intermediate shaft from the steering gear.
8. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement
(See: Suspension/Stabilizer Bar/Stabilizer
Link/Service and Repair/Front Suspension) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13045
9. Remove the steering gear to cradle mounting bolts.
10. Remove the steering gear through the right side of the vehicle. 11. With heat shield equipped
steering gears, remove the heat shield. Save for installation.
Installation Procedure
1. If applicable, install the heat shield.
Important: Ensure the stabilizer is swung in the upmost position for gear clearance.
2. Install the steering gear from the right side of the vehicle.
3. Center the gear mounting bushings into the cradle supports.
Notice: Refer to Fastener Notice .
4. Hand start both steering gear to cradle mounting bolts.
Tighten the bolts to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13046
5. Connect the intermediate shaft to the steering gear and install a new pinch bolt.
Tighten the intermediate pinch bolt to 34 N.m (25 lb ft).
6. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement (See:
Suspension/Stabilizer Bar/Stabilizer
Link/Service and Repair/Front Suspension) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13047
Important: Hold the ball stud to prevent turning during installation of the nut.
7. Connect the tie rod to the knuckle and install a new nut.
Tighten the nut to 25 N.m (18 lb ft) plus 90 degrees.
8. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Wheels
and Tires/Service and Repair) . 9. Check the front wheel alignment and align as necessary. Refer
to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel
Alignment Measurement) .
10. Lower the vehicle.
Steering Gear Replacement (Hydraulic Power Steering)
Steering Gear Replacement (HPS)
Removal Procedure
1. Disconnect the rack and pinion outer tie rods from the steering knuckles. Refer to Rack and
Pinion Outer Tie Rod End Replacement (See: Tie
Rod/Tie Rod End/Service and Repair) .
2. Remove the intermediate steering shaft lower bolt. Refer to Intermediate Steering Shaft
Replacement (See: Steering Column/Service and
Repair/Intermediate Steering Shaft Replacement) .
3. Place drain pans under the vehicle as needed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13048
4. Remove the transaxle mount bolt (1).
5. Remove the transaxle mount bolts (1) and position the transaxle mount aside.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13049
Important: Do not reuse the old O-Ring seals.
6. Disconnect the power steering gear inlet hose (2) and the power steering cooler hose (1) from
the power steering gear.
7. Remove the power steering gear hoses bracket bolt (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13050
8. Remove the power steering gear bolts (1). 9. Remove the power steering gear through the left
wheel house area.
10. Transfer any parts as needed.
Installation Procedure
1. Position the power steering gear into the vehicle through the left wheel house area.
Notice: Refer to Fastener Notice .
2. Install the power steering gear bolts (1).
Tighten to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13051
3. Install the power steering gear hoses bracket bolt (1).
Tighten to 9 N.m (80 lb in).
Important: New O-Ring seals must be used to avoid potential leaks.
4. Connect the power steering gear inlet hose (2) and the power steering fluid cooler hose (1) to
the power steering gear.
Tighten to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service
and Repair > Steering Gear Boot Replacement - Off Vehicle > Page 13052
5. Install the transaxle mount and transaxle mount bolts (1).
Tighten to 50 N.m (37 lb ft).
6. Install the transaxle mount bolt (1).
Tighten to 110 N.m (81 lb ft).
7. Clean any excess fluid from the vehicle and remove the drain pans. 8. Install the intermediate
steering shaft lower bolt. Refer to Intermediate Steering Shaft Replacement (See: Steering
Column/Service and
Repair/Intermediate Steering Shaft Replacement) .
9. Connect the rack and pinion outer tie rods to the steering knuckles. Refer to Rack and Pinion
Outer Tie Rod End Replacement (See: Tie Rod/Tie
Rod End/Service and Repair) .
10. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See:
Power Steering/Power Steering Bleeding/Service and
Repair) .
11. Adjust the front toe. Refer to Front Toe Adjustment (See: Alignment/Service and Repair/Front
Toe Adjustment) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Assembly > Component
Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement (Equinox)
Removal Procedure
1. Use a small flat-bladed tool to release the switch assembly from the steering wheel. 2.
Disconnect the cruise switch electrical harness connector from the switch.
Installation Procedure
1. Connect the switch electrical harness connector to the switch. Push in the connector until a click
is heard and pull back to confirm a positive
engagement.
2. Insert the cruise switch into the steering wheel and gently apply pressure to fasten the switch in
the opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter >
Component Information > Locations
Steering Mounted Controls Transmitter: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Horn Switch 2 - Steering Wheel Control Switch - Right (UK3/K34) 3 - Steering Wheel Control
Switch - Left (UK3/K34)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter >
Component Information > Locations > Page 13059
Steering Mounted Controls Transmitter: Diagrams
Component Connector End Views - Continued
Steering Wheel Control Switch - Left
Steering Wheel Control Switch - Right (UK3)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter >
Component Information > Locations > Page 13060
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service
and Repair
Steering Shaft: Service and Repair
Intermediate Steering Shaft Replacement
Removal Procedure
Notice: Secure the steering wheel utilizing a strap to prevent rotation. Locking of the steering
column will prevent damage and a possible malfunction of the SIR system. The steering wheel
must be secured in position before disconnecting the following components:
* The steering column
* The intermediate shaft
* The steering gear
After disconnecting these components, do not move the front tires and wheels. Failure to follow
these procedures may cause improper alignment of some components during installation and
result in possible damage to the SIR coil.
1. With the steering wheel in the straight forward position, remove the ignition key.
2. Remove the intermediate steering shaft to steering gear pinch bolt. Discard the bolt. 3.
Disengage the intermediate shaft seal from the body panel. 4. Collapse the intermediate steering
shaft, while disconnecting the intermediate steering shaft from the steering gear. 5. Place scribe
makes on the intermediate shaft to the steering column connection prior to removal.
6. Remove the intermediate shaft pinch bolt at the steering column. Discard the pinch bolt. 7.
Disconnect the intermediate steering shaft from the steering column.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service
and Repair > Page 13064
8. Remove the intermediate steering shaft assembly from inside the vehicle.
Installation Procedure
Important: Failure to transfer the pre-scribed marks may result in an off-center steering wheel.
1. If installing a new intermediate shaft, transfer the pre-scrubed alignment marks on to the new
part.
2. Install the intermediate steering shaft assembly from inside the vehicle.
3. Align and connect the intermediate steering shaft to the steering gear.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service
and Repair > Page 13065
Notice: Refer to Fastener Notice .
4. Install a new lower intermediate shaft pinch bolt.
Tighten the bolt to 34 N.m (25 lb ft).
5. Align the pre-scribed mark on the intermediate steering shaft to the pre-scribed mark on the
steering column.
6. Connect the intermediate steering shaft to the steering column. 7. If the intermediate shaft was
removed without the use of scribed marks, perform the following:
1. Place the road wheels in the straight ahead position. 2. Align the steering column shaft notch in
the 12 o'clock position and connect the intermediate shaft to the steering column. 3. Install a new
upper intermediate shaft pinch bolt.
Tighten the bolt to 34 N.m (25 lb ft).
8. Seat the intermediate shaft seal into the body panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation
Steering Wheel: Description and Operation
Steering Wheel and Column Description and Operation
The steering wheel and column has 4 primary functions:
* Vehicle steering
* Vehicle security
* Driver convenience
* Driver safety
Vehicle Steering
The steering wheel is the first link between the driver and the vehicle. The steering wheel is
fastened to a steering shaft within the column. At the lower end of the column, the intermediate
shaft connects the column to the steering gear.
Vehicle Security-Some Vehicle Models
Theft deterrent components are mounted and designed into the steering column. The following
components allow the column to be locked in order to minimize theft:
* The ignition switch
* The steering column lock
* The ignition cylinder
Driver Convenience
The steering wheel and column may also have driver controls attached for convenience and
comfort. The following controls may be mounted on or near the steering wheel or column.
* The turn signal switch
* The hazard switch
* The headlamp dimmer switch
* The wiper/washer switch
* The horn pad/cruise control switch
* The tilt or tilt/telescoping functions
Driver Safety
The energy-absorbing steering column compresses in the event of a front-end collision, which
reduces the chance of injury to the driver. The mounting capsules break away from the mounting
bracket in the event of an accident.
Ignition Lock Cylinder Control Actuator
If the vehicle is equipped with a floor mounted console gear shifter, it has a ignition lock cylinder
control actuator system in the steering column. The ignition lock cylinder control actuator's purpose
is to prevent the ignition key from being turned to the OFF position when the transmission is in gear
and the vehicle may still be moving. The column ignition lock system consists of a ignition lock
cylinder control actuator , and a Park position switch that is located in the automatic transmission
(A/T) shift lock control switch. The ignition lock cylinder control actuator contains a pin that is spring
loaded out to mechanically prevent the ignition key cylinder from being turned to the Lock position
when vehicle transmission is not in the Park position. If vehicle power is lost, and/or the
transmission is not in the Park position the operator will not be able to turn the ignition key to the
Lock position and will not be able to remove the ignition key from the column.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 13069
Steering Wheel: Service and Repair
Steering Wheel Replacement
Tools Required
* J 42578 Steering Wheel Puller Legs
* J 1859-A Steering Wheel Puller
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling . 2. Remove the inflatable restraint
steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement
(Equinox) Inflatable
Restraint Steering Wheel Module Replacement (Torrent) .
3. If equipped with cruise control, disconnect the cruise control switch connector from the steering
column. 4. Remove the steering wheel nut. 5. Remove the steering wheel. It may be necessary to
use the J 42578 and J 1859-A or equivalent to remove the steering wheel.
Installation Procedure
1. Align the steering wheel to the steering column and install the steering wheel.
Notice: Refer to Fastener Notice .
2. Install the steering wheel nut.
Tighten the steering wheel nut to 41 N.m (30 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Description and Operation > Page 13070
3. If equipped with cruise control, connect the cruise control switch connector. 4. Install the
inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module
Replacement (Equinox) Inflatable
Restraint Steering Wheel Module Replacement (Torrent) .
5. Enable the SIR system. Refer to SIR Disabling and Enabling .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair
Tie Rod End: Service and Repair
Rack and Pinion Outer Tie Rod End Replacement
Tools Required
J 24319-B Steering Linkage and Tie Rod Puller
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the front tire
assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
Important: Mark the location of the jam nut for installation.
3. Loosen the tie rod inner jam nut.
Important: Hold the ball stud to prevent turning during removal of the nut.
4. Remove the tie rod to knuckle nut. Discard the nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Page 13075
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
5. Use the J 24319-B to separate the tie rod from the steering knuckle.
6. Remove the outer tie rod from the inner tie rod.
Installation Procedure
1. Install the outer tie rod to the inner tie rod. 2. Connect the tie rod to the knuckle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Page 13076
Notice: Refer to Fastener Notice .
3. Install a new tie rod retention nut.
Tighten the nut to 25 N.m+90 degrees (18 lb ft)+90 degrees.
4. Install the front tire assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels
and Tires/Service and Repair) . 5. Check the wheel alignment. Refer to Wheel Alignment
Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair
Axle Beam: Service and Repair
Support Replacement (AWD Vehicles)
Tools Required
J 37043 Park Brake Cable Release Tool
Removal Procedure
1. Place the park brake lever in the release position. 2. Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle . 3. Remove the tires and wheels. Refer to Tire and Wheel Removal
and Installation (See: Wheels and Tires/Service and Repair) . 4. Remove the exhaust muffler.
Refer to Exhaust System Replacement (LNJ) Exhaust System Replacement (LY7) .
5. Remove the rear park brake cable routing bolts from the trailing arms.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair > Page 13081
6. Disconnect the rear park brake cables from the park brake actuators. 7. Using the J 37043 ,
remove the park brake cables from the mounting brackets 8. Position the rear park brake cables
aside. 9. Disconnect the rear wheel speed sensor electrical connectors and routing clips from the
rear support and upper control arms.
Position the wiring harness aside.
10. Remove the rear brake hose bracket nut and bolt.
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
11. Remove the brake calipers and brackets as assemblies and support them with heavy
mechanics wire or equivalent. Refer to Rear Brake Caliper
Bracket Replacement .
12. While holding the stabilizer link with a wrench, remove the stabilizer link-to-lower control arm
nut. 13. Remove the trailing arms. Refer to Trailing Arm Replacement (See: Trailing Arm/Service
and Repair/Trailing Arm Replacement) . 14. Remove the adjustment links. Refer to Adjust Link
Replacement (See: Steering/Tie Rod/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair > Page 13082
15. Remove the rear wheel drive shafts. Refer to Rear Wheel Drive Shaft Replacement (See:
Transmission and Drivetrain/Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Service and Repair/Rear Wheel Drive Shaft Replacement) .
16. Remove the rear differential. Refer to Differential Replacement (See: Transmission and
Drivetrain/Differential Assembly/Service and
Repair/Removal and Replacement/Differential Replacement) .
17. Position a transmission jack under the rear support and firmly secure the support to the jack
with straps.
18. Remove the 4 rear support to body bolts. 19. Remove the rear support assembly from the
vehicle. 20. With the aid of an assistant, remove the rear support from the transmission jack and
place it on the floor.
Installation Procedure
Notice: Refer to Fastener Notice .
1. If a new rear support is being installed, a transfer of components is necessary.
* Upper Control Arms
Tighten the upper control arm to rear support nut and bolt to 160 N.m (118 lb ft).
* Lower Control Arms
Tighten the lower control arm to rear support nut and bolt to 110 N.m (81 lb ft).
* Stabilizer bar and insulators
- Tighten the stabilizer shaft insulator clamp bolts to 70 N.m (52 lb ft).
- Tighten the stabilizer link to stabilizer shaft nut to 57 N.m (42 lb ft).
* Knuckles - Loosely install the upper and lower control arm to knuckle nuts/bolts. These fasteners
will be tightened later in this procedure after the wheel driveshafts are installed.
2. With the aid of an assistant, position the rear support onto the transmission jack and firmly
secure the support to the jack with straps. 3. Position the rear support assembly to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair > Page 13083
4. Install the 4 rear support to body bolts.
Tighten the rear support to body bolts to 170 N.m (125 lb ft).
5. Install the rear differential. Refer to Differential Replacement (See: Transmission and
Drivetrain/Differential Assembly/Service and
Repair/Removal and Replacement/Differential Replacement) .
6. Install the rear wheel drive shafts. Refer to Rear Wheel Drive Shaft Replacement (See:
Transmission and Drivetrain/Drive Axles, Bearings and
Joints/Axle Shaft Assembly/Service and Repair/Rear Wheel Drive Shaft Replacement) .
7. Install the adjustment links. Refer to Adjust Link Replacement (See: Steering/Tie Rod/Service
and Repair) . 8. Install the trailing arms. Refer to Trailing Arm Replacement (See: Trailing
Arm/Service and Repair/Trailing Arm Replacement) .
9. While holding the stabilizer link, install the stabilizer link-to-lower control arm nut.
Tighten the stabilizer link to lower control arm nut to 15 N.m (11 lb ft).
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair > Page 13084
may cause damage to the brake hose and in turn may cause a brake fluid leak.
10. Remove the supporting wire and position the brake caliper and bracket assemblies back onto
the knuckles. Refer to Rear Brake Caliper Bracket
Replacement .
11. Install the rear brake hose bracket nut and bolt.
Tighten the rear brake hose bolt and nut to 12 N.m (106 lb in).
12. Position the wiring harness back to the original location, connect the routing clips to the rear
support and upper control arms.
Connect the rear wheel speed sensor electrical connectors.
13. Connect the rear park brake cables through the mounting brackets and onto the park brake
actuators.
14. Install the rear park brake cable routing bolts to the trailing arms.
Tighten the rear park brake cable routing bolt to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service
and Repair > Page 13085
15. Install the exhaust muffler. Refer to Exhaust System Replacement (LNJ) Exhaust System
Replacement (LY7) . 16. Install the tires and wheels. Refer to Tire and Wheel Removal and
Installation (See: Wheels and Tires/Service and Repair) . 17. Check the rear alignment. Refer to
Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment
Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information >
Specifications
Ball Joint: Specifications
Wear Limit Gently lift or pry the suspension to induce ball joint movement. If the dial indicator
indicates a reading greater than 3.18 mm (0.125 in), replace the ball joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information >
Specifications > Page 13089
Ball Joint: Testing and Inspection
Ball Joint Inspection
Tools Required
J 8001 Dial Indicator Set
Important: *
The vehicle must rest on a level surface.
* The vehicle must be stable. Do not rock the vehicle on the floor stands.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Clean and inspect the
ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint. Refer to Lower
Control Arm Ball Joint
Replacement (See: Service and Repair) .
3. Support the lower control arm with a floor stand as far outboard as possible and raise the
suspension to just below ride height.
4. Install the J 8001 or suitable dial indicator in a way to measure vertical lash in the ball joint.
Notice: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may
result.
5. Gently lift or pry the suspension to induce ball joint movement. 6. If the dial indicator indicates a
reading greater than 3.18 mm (0.125 in), replace the ball joint. Refer to Lower Control Arm Ball
Joint Replacement
(See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information >
Specifications > Page 13090
Ball Joint: Service and Repair
Lower Control Arm Ball Joint Replacement
Removal Procedure
1. Remove the lower control arm. Refer to Lower Control Arm Replacement (See: Control
Arm/Service and Repair/Front Suspension) . 2. Place the control arm in a vise or suitable holding
device. 3. Remove the ball joint rivets using the following procedure.
1. Drill through the rivets using a 8 mm (5/16 in) drill bit. 2. Enlarge the hole using a 12 mm (31/64
in) drill bit. 3. Remove any remaining burs from the control arm.
4. Remove the ball joint from the control arm. Note the position of the ball joint for reassembly.
Installation Procedure
Important: The control arm must be clean and free of debris.
1. Install the ball joint to the control arm as previously noted.
Notice: Refer to Fastener Notice .
Important: *
Only use hardware provided with the new ball joint.
* The bolts must be installed with the bolt head on top of the ball joint.
2. Install the ball joint to control arm bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information >
Specifications > Page 13091
Tighten the bolts and nuts to 68 N.m (50 lb ft).
3. Install the lower control arm. Refer to Lower Control Arm Replacement (See: Control
Arm/Service and Repair/Front Suspension) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 08-02-35-003A > Jun
> 09 > Steering/Suspension - Noise/Looseness In Steering Column
Control Arm Bushing: Customer Interest Steering/Suspension - Noise/Looseness In Steering
Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: >
08-02-35-003A > Jun > 09 > Steering/Suspension - Noise/Looseness In Steering Column
Control Arm Bushing: All Technical Service Bulletins Steering/Suspension - Noise/Looseness In
Steering Column
ENGINEERING INFORMATION
Bulletin No.: 08-02-35-003A
Date: June 03, 2009
Subject: EI08116 - Noise/Looseness in Steering Column (Engineering
Recommendations/Engineering Information Closed)
Models:
2008 Chevrolet Equinox 2008 Pontiac Torrent
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
end the need for additional information from the field and to offer engineering recommendations to
correct this customer concern. Please discard Corporate Service Bulletin Number 08-02-35-003
(Section - 02 Steering).
..............................................................................................................................................................
..................................................................................
Condition
Some customers may comment on noise coming from the steering column or a loose steering
column.
Engineering Revisions and Recommendations
Engineering has made the following revisions and recommendations for eliminating the customer
concern
1. Verify that the vehicle has upgraded software for the Electronic Power Steering (EPS) calibration P/N 25883852 or later. 2. To reduce steering column noise refer to and perform
Corporate Bulletin Number 07-03-08-004 - Rattle Noise in Front of Vehicle While Driving
Over Rough Road Surfaces (Replace Both Front Lower Control Arm Rear Bushings).
3. Refer to revised SI diagnostics and service procedures along with improved Tech 2(R) assisted
steering column alignment procedures (when
moving steering fully extended from right to left).
Engineering is satisfied with the data that was collected and requires no further responses on this
issue.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing >
Component Information > Technical Service Bulletins > Page 13106
Control Arm Bushing: Service and Repair
Front Lower Control Arm Bushing Replacement (Rear Bushing)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the front tire
and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) . 3. Remove the lower control arm. Refer to Lower Control Arm
Replacement (See: Service and Repair/Front Suspension) .
4. Remove the rear bushing nut. 5. Remove the rear bushing.
Installation Procedure
Notice: Refer to Fastener Notice .
1. Install the rear bushing to the lower control arm.
Tighten the nut to 150 N.m (110 lb ft).
2. Install the lower control arm. Refer to Lower Control Arm Replacement (See: Service and
Repair/Front Suspension) . 3. Install the front tire and wheel assembly. Refer to Tire and Wheel
Removal and Installation (See: Wheels and Tires/Service and Repair) . 4. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Service and Repair
Cross-Member: Service and Repair
Drivetrain and Front Suspension Frame Reinforcement Replacement (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension
Front Steering Knuckle: Service and Repair Rear Suspension
Knuckle Replacement
Special Tools
J 37043 Park Brake Cable Release Tool
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) .
3. Disconnect the rear park brake cable from the park brake actuator. 4. Using the J 37043 ,
remove the park brake cable from the mounting bracket
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper
in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanics wire
or equivalent. Refer to Rear Brake Caliper Bracket
Replacement .
6. Remove the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Rear
Suspension) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13114
7. Remove the upper control arm to knuckle bolt and nut.
8. Remove the lower control arm to knuckle bolt and nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13115
9. Remove the toe link to knuckle bolt and nut.
10. Remove the 3 trailing arm to knuckle bolts. 11. Remove the knuckle from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13116
1. Install the knuckle to the lower control arm. Loosely install the bolt and nut.
2. Install the knuckle to the upper control arm. Loosely install the bolt and nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13117
3. Install the knuckle to the toe link. Loosely install the bolt and nut.
4. Install the 3 trailing arm to knuckle bolts. Loosely install the bolt and nut.
Notice: Refer to Fastener Notice .
5. Tighten the bolts and nuts in the following sequence:
* Tighten the knuckle to lower control arm bolt and nut to 160 N.m (118 lb ft).
* Tighten the knuckle to upper control arm bolt and nut to 160 N.m (118 lb ft).
* Tighten the knuckle to toe link bolt and nut to 160 N.m (118 lb ft).
* Tighten the 3 trailing arm to knuckle bolts to 110 N.m (81 lb ft).
6. Install the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Rear
Suspension) .
Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated
from its mount and the hydraulic flexible
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13118
brake hose is still connected. Failure to support the caliper in this manner will cause the flexible
brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in
turn may cause a brake fluid leak.
7. Remove the supporting wire and position the brake caliper and bracket assemblies back onto
the knuckles. Refer to Rear Brake Caliper Bracket
Replacement .
8. Connect the rear park brake cable through the mounting bracket and onto the park brake
actuator. 9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
10. Lower the vehicle. 11. Perform a vehicle wheel alignment. Refer to Wheel Alignment
Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement
).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13119
Front Steering Knuckle: Service and Repair Front Suspension
Steering Knuckle Replacement
Special Tools
J-42188-B Ball Joint Separator
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) . 3. Remove the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub
Replacement (See: Wheel Bearing/Service and Repair/Front
Suspension) .
Important: Do not allow the stabilizer link ball stud to rotate while removing the link nut.
4. Remove the nut and separate the stabilizer link from the strut assembly. 5. Loosen the steering
knuckle to strut bolts and nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13120
6. Remove and discard the lower ball joint cotter pin. 7. Loosen the ball stud nut, until level with the
top of the ball stud. 8. Using the J-42188-B , separate the lower ball joint from the steering knuckle.
9. Remove the lower ball joint nut and separate from the knuckle.
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
10. Remove the outer tie rod end from the knuckle. Refer to Rack and Pinion Outer Tie Rod End
Replacement (See: Steering/Tie Rod/Tie Rod
End/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13121
11. Remove the steering knuckle to strut bolts and nuts. 12. Remove the steering knuckle from the
vehicle.
Installation Procedure
1. Position the steering knuckle to strut assembly.
2. Loosely install the strut to steering knuckle bolts and nuts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13122
3. Position the lower ball joint stud into the steering knuckle.
Notice: Refer to Fastener Notice .
4. Install the ball stud nut.
Tighten the nut to 40 N.m (30 lb ft) .
5. Tighten the strut to steering knuckle bolts and nuts.
Tighten the bolts and nuts to 180 N.m (133 lb ft).
Important: Do not loosen the castle nut for cotter pin installation.
6. Tighten the castle nut enough to allow for cotter pin installation.
Important: The cotter pin must not contact the wheel speed sensor or drive axle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information
> Service and Repair > Rear Suspension > Page 13123
7. Install a new cotter pin. 8. Install the outer tie rod end to the knuckle. Refer to Rack and Pinion
Outer Tie Rod End Replacement (See: Steering/Tie Rod/Tie Rod
End/Service and Repair) .
Important: Do not allow the stabilizer link ball stud to rotate while installing the link nut.
9. Position the stabilizer shaft link to the strut assembly and install the nut.
Tighten the nut to 65 N.m (48 lb ft).
10. Install the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Front
Suspension) .
11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) . 12. Lower the vehicle. 13. Perform a wheel alignment. Refer to Wheel
Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering
Angle Sensor > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing
> Component Information > Service and Repair > Front Suspension
Stabilizer Bushing: Service and Repair Front Suspension
Stabilizer Shaft Insulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing
> Component Information > Service and Repair > Front Suspension > Page 13133
Stabilizer Bushing: Service and Repair Rear Suspension
Stabilizer Shaft Insulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension
Stabilizer Link: Service and Repair Front Suspension
Stabilizer Shaft Link Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 13138
Stabilizer Link: Service and Repair Rear Suspension
Stabilizer Shaft Link Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear tire
and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
3. Loosen the stabilizer shaft clamp bolts.
Important: Hold the ball shaft secure with a TORX(R) bit, when removing the nut.
4. Remove the stabilizer link to stabilizer shaft nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 13139
Important: When disconnecting the stabilizer link, hold the link with a wrench to prevent turning.
5. Remove the stabilizer link to lower control arm nut. 6. Remove the stabilizer link from the vehicle.
Installation Procedure
1. Position the stabilizer link through the lower control arm.
Notice: Refer to Fastener Notice .
Important: When connecting the stabilizer link, hold the link with a wrench to prevent turning.
2. Install the stabilizer link to lower control arm nut.
Tighten the nut to 15 N.m (11 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension > Page 13140
Important: Hold the ball shaft secure with a TORX(R) bit, when installing the nut.
3. Install the stabilizer link to stabilizer shaft nut.
Tighten the nut to 50 N.m (37 lb ft).
4. Tighten the loose stabilizer shaft clamp bolts.
Tighten the bolts to 70 N.m (52 lb ft).
5. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) . 6. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide
Front Strut / Shock Tower: Customer Interest Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13150
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13151
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13152
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13153
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A >
Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13154
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide
Front Strut / Shock Tower: All Technical Service Bulletins Body - General Water Leak Diagnostic
Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13160
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13161
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13162
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13163
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 13164
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13165
Front Strut / Shock Tower: By Symptom
Technical Service Bulletin # 08-08-57-001A Date: 081008
Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13166
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13167
Water may be entering between the liftgate and the weatherstrip.
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13168
Condition 6
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13169
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13170
Parts Information
Disclaimer
Technical Service Bulletin # 08-08-57-001A Date: 081008
Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13171
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13172
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13173
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13174
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Front Strut / Shock Tower
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page
13175
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair
Front Subframe: Service and Repair
Frame Replacement (LNJ)
Tools Required
* J 43828 Ball Joint Remover
* SA9140E Torque Angle Gage
Removal Procedure
1. Secure the radiator to the upper radiator support. 2. Raise and support the vehicle. refer to
Vehicle Lifting. 3. Remove the front wheels. 4. Remove the side splash shield-to-frame fasteners.
5. Remove the front air dam-to-frame fasteners.
6. Remove the rear transaxle mount-to-frame bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair > Page 13180
7. Remove the front transaxle mount through bolt.
8. Remove the steering gear-to-frame bolts. 9. Using mechanics wire, secure the steering gear to
the exhaust.
10. Remove the stabilizer shaft clamp-to-frame bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair > Page 13181
11. Remove the lower ball joint cotter pins. Discard the cotter pins.
12. Loosen the lower ball joint castle nut until the nut is level with the top of the ball stud.
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
13. Using the J 43828, separate the lower control arm from the steering knuckle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair > Page 13182
14. Remove the frame-to-body bolts. Discard the bolts. 15. Carefully lower the frame from the
vehicle. 16. Remove the lower control arms.
Installation Procedure
1. Install the lower control arms. 2. Raise the frame to the body.
Important: Do not tighten the fasteners at this time.
3. Loosely install new frame-to-body bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair > Page 13183
4. Connect the ball joint stud to the steering knuckle.
Notice: Refer to Fastener Notice.
5. Install the ball stud castle nut.
Tighten the nut to 40 N.m (30 lb in).
Important:
* Do not loosen the castle nut in order to align the cotter pin slots.
* Ensure the cutter pin ends do not contact the wheel speed sensor harness.
Continue to tighten the castle nut to align the slots with the opening in the ball stud and install the
ball stud cotter pin.
7. Remove the mechanics wire and install the steering gear to the frame.
Tighten the bolts to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System
Information > Service and Repair > Page 13184
8. Install the front transaxle mount through bolt.
Tighten the bolt to 110 N.m (81 lb ft).
9. Install the rear transaxle mount-to-frame bolts.
Tighten the bolts to 50 N.m (37 lb ft).
10. Install the stabilizer shaft clamp.
Tighten the bolts to 50 N.m (37 lb ft).
11. Tighten the frame-to-body bolts.
Tighten the bolts to 155 N.m (114 lb ft).
12. Install the front air dam fasteners. 13. Install the side splash shield-to-frame fasteners. 14.
Install the front wheels. 15. Lower the vehicle. 16. Release the radiator from the upper radiator
support. 17. Align the front suspension. Refer to Front Toe Adjustment.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring
Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension Coil Spring
Strut, Strut Component, and Spring Replacement
Tools Required
* J 42991 Strut Rod Nut Socket
* J 45400 Strut Spring Compressor
Removal Procedure
1. Install the strut assembly in the J 45400 using the following procedure.
1. Adjust the lower legs of the J 45400 to the lowest possible coil of the spring. 2. Adjust the upper
legs of the J 45400 to the highest possible coil of the spring. 3. Inspect the strut assembly to insure
hooks on the strut compress legs are properly installed on the spring coils. 4. Verify the strut
assembly is parallel with the J 45400 .
2. Compress the spring enough to unload the upper strut mount.
Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to
keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage
to the absorber may occur.
3. Use the J 42991 or equivalent hand tools to remove the strut shaft nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13189
Important: Leave the spring in the spring compressor.
4. Lower the strut from the spring assembly.
Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount
assembly by the metal portion when removing/installing the top mount from/to the strut assembly.
Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing
components and cause the bearing to fall apart.
5. Remove the upper mount assembly, inspect for damage and deterioration. Replace as
necessary. 6. Remove the strut dust shield and inspect for damage and deterioration. Replace as
necessary. 7. Remove the hollow bumper from the strut shaft and inspect for damage and
deterioration. Replace as necessary. 8. Inspect the spring for damage. Replace as necessary.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13190
1. Extend the strut to its limit of travel. 2. Install the hollow bumper and dust boot to the strut shaft.
Important: The tag identifying the spring will be closer to the bottom of the spring. The end of the
coil sits up against the tab on the spring seat.
3. With the spring in the compressor, install the strut into the spring.
Important: The anti-rotation tab on the spring seat must face 180 degrees from the direction that
the knuckle bracket points.
4. Assemble the upper spring seat onto the strut shaft and align the flat with the strut to knuckle
mounting bracket.
Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount
assembly by the metal portion when removing/installing the top mount from/to the strut assembly.
Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing
components and cause the bearing to fall apart.
Important: The flat on the metal plate of the top mount assembly must face the same direction of
the anti-rotation tab on the spring seat.
5. Assemble the top mount onto the strut shaft and align the flat 180 degrees from flat on the upper
spring seat.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13191
6. Loosely install the strut shaft nut.
Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to
keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage
to the absorber may occur.
Notice: Refer to Fastener Notice .
7. Hold the strut shaft and use the J 42991 or equivalent hand tools to tighten the shaft while
verifying that the upper spring seat flats align with the
top mount.
Tighten the strut shaft to 55 N.m (41 lb ft).
8. Release the tension on the J 45400 . 9. Remove the strut assembly from the J 45400 .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13192
Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring
Coil Spring Replacement
Coil Spring Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear tire
and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) . 3. Remove the stabilizer shaft link. Refer to Stabilizer Shaft Link
Replacement (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Rear
Suspension) .
4. Position a jackstand underneath the lower control arm. 5. Raise the jackstand slightly to
compress the coil spring.
6. Remove the lower shock bolt and nut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13193
7. Loosen the lower control arm to support frame nut and bolt.
8. Remove the lower control arm to knuckle nut and bolt. 9. Slowly lower the control arm in order to
unload the coil spring.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13194
10. Remove the coil spring and insulators.
Installation Procedure
1. Inspect the coil spring upper and lower insulators, if damage exists replace the insulators.
If no damage exists, transfer the existing components. Refer to Coil Spring Insulators Replacement
(See: Coil Spring Insulators Replacement) .
2. Position the spring with the rubber insulators into the vehicle. 3. Raise the jackstand to compress
the spring.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13195
Notice: Refer to Fastener Notice .
4. Position the lower control arm to the knuckle and install the nut and bolt.
Tighten the lower control arm to knuckle bolt and nut to 160 N.m (118 lb ft).
5. Tighten the lower control arm to support nut and bolt.
Tighten the bolt to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13196
6. Install the shock to the lower control arm nut and bolt.
Tighten the lower shock bolt and nut to 110 N.m (81 lb ft).
7. Remove the jackstand from under the vehicle. 8. Install the stabilizer shaft link. Refer to
Stabilizer Shaft Link Replacement (See: Stabilizer Bar/Stabilizer Link/Service and Repair/Rear
Suspension) .
9. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
10. Lower the vehicle.
Coil Spring Insulators Replacement
Coil Spring Insulators Replacement
Removal Procedure
1. Remove the coil spring. Refer to Coil Spring Replacement (See: Coil Spring Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front Suspension Coil Spring > Page 13197
2. Remove the upper and lower rubber insulators from the coil spring.
Installation Procedure
Important: *
Spray silicon lubricant on the insulators to aid in installation.
* Make sure that part number identification tape located on the coil spring is oriented outboard of
the vehicle and at the top of the spring.
* Make sure to fully seat the top and bottom coil spring insulators to the spring.
1. Install the upper and lower rubber insulators to the coil spring. 2. Install the coil spring. Refer to
Coil Spring Replacement (See: Coil Spring Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information
Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock
Absorber/Strut Leakage Information
INFORMATION
Bulletin No.: 05-03-08-002C
Date: October 16, 2009
Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks
Models:
2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures.
Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension).
This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage.
Improper diagnosis may lead to components being replaced that are within the manufacturer's
specification. Shock absorbers and strut assemblies are fluid-filled components and will normally
exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the
shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage.
Use the following information to determine if the condition is normal acceptable seepage or a
defective component.
Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to
this oil film. Often this film and dust can be wiped off and will not return until similar mileage is
accumulated again.
Inspection Procedure
Note
The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform
the following inspection procedure.
Use the following descriptions and graphics to determine the serviceability of the component.
Shock Absorbers
Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the
shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or
less of the lower shock tube (A) and originating from the shaft seal.
Replace shock absorbers displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet
film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal.
Coil-over Shock Absorber
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 13202
Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock
absorber components and not originating from the
shaft seal (located at the top of the coil-over shock tube).
2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the
shaft seal.
Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet
film of oil covering the shock absorber tube and pooling in the spring seat and originating from the
shaft seal.
Struts
Do Not Replace Struts displaying condition 1 or 2 levels of seepage.
1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not
originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and
originating from the shaft seal.
Replace Struts displaying conditions 3 and 4 levels of leaks.
3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the
strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and
originating from the shaft seal.
Correction
Use the information published in SI for diagnosis and repair.
Use the applicable published labor operation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut
Suspension Strut / Shock Absorber: Service and Repair Front Suspension Strut
Suspension Strut Disposal
Suspension Strut Disposal
Caution: Use the proper eye protection when drilling to prevent metal chips from causing physical
injury.
1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the
strut at the center of the end cap (3) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will
exhaust when the drill bit
penetrates the strut. Use shop towels in order to contain the escaping oil.
3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down.
5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut.
Strut Assembly Replacement
Strut Assembly Replacement
Removal Procedure
1. Remove the 3 upper strut mount bolts. 2. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle . 3. Remove the wheel and tire assembly. Refer to Tire and Wheel Removal
and Installation (See: Wheels and Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13205
4. Remove the brake hose bracket bolt from the strut assembly.
5. Remove the stabilizer link nut and separate the link from the strut assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13206
6. Remove the lower strut bolts and nuts. 7. Remove the strut assembly from the vehicle.
Installation Procedure
1. Position the strut assembly to the vehicle.
Notice: Refer to Fastener Notice .
2. Install the 3 upper strut mount bolts.
Tighten the upper strut mount bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13207
3. Install the lower strut bolts and nuts.
Tighten the bolts and nuts to 200 N.m (148 lb ft).
Important: Inspect the stabilizer link seals for damage prior to installation. Replace as required.
Important: Do not allow the stabilizer link ball stud to rotate while installing the link nut.
4. Position the stabilizer link to the strut and install the nut.
Tighten the nut to 65 N.m (48 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13208
5. Position the brake hose bracket to the strut assembly and install the bolt.
Tighten the brake bracket bolt to 15 N.m (11 lb ft).
6. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) . 7. Lower the vehicle. 8. Perform a wheel alignment. Refer to Wheel
Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) .
Strut, Strut Component, and Spring Replacement
Strut, Strut Component, and Spring Replacement
Tools Required
* J 42991 Strut Rod Nut Socket
* J 45400 Strut Spring Compressor
Removal Procedure
1. Install the strut assembly in the J 45400 using the following procedure.
1. Adjust the lower legs of the J 45400 to the lowest possible coil of the spring. 2. Adjust the upper
legs of the J 45400 to the highest possible coil of the spring. 3. Inspect the strut assembly to insure
hooks on the strut compress legs are properly installed on the spring coils. 4. Verify the strut
assembly is parallel with the J 45400 .
2. Compress the spring enough to unload the upper strut mount.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13209
Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to
keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage
to the absorber may occur.
3. Use the J 42991 or equivalent hand tools to remove the strut shaft nut.
Important: Leave the spring in the spring compressor.
4. Lower the strut from the spring assembly.
Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount
assembly by the metal portion when removing/installing the top mount from/to the strut assembly.
Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing
components and cause the bearing to fall apart.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13210
5. Remove the upper mount assembly, inspect for damage and deterioration. Replace as
necessary. 6. Remove the strut dust shield and inspect for damage and deterioration. Replace as
necessary. 7. Remove the hollow bumper from the strut shaft and inspect for damage and
deterioration. Replace as necessary. 8. Inspect the spring for damage. Replace as necessary.
Installation Procedure
1. Extend the strut to its limit of travel. 2. Install the hollow bumper and dust boot to the strut shaft.
Important: The tag identifying the spring will be closer to the bottom of the spring. The end of the
coil sits up against the tab on the spring seat.
3. With the spring in the compressor, install the strut into the spring.
Important: The anti-rotation tab on the spring seat must face 180 degrees from the direction that
the knuckle bracket points.
4. Assemble the upper spring seat onto the strut shaft and align the flat with the strut to knuckle
mounting bracket.
Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount
assembly by the metal portion when removing/installing the top mount from/to the strut assembly.
Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing
components and cause the bearing to fall apart.
Important: The flat on the metal plate of the top mount assembly must face the same direction of
the anti-rotation tab on the spring seat.
5. Assemble the top mount onto the strut shaft and align the flat 180 degrees from flat on the upper
spring seat.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13211
6. Loosely install the strut shaft nut.
Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to
keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage
to the absorber may occur.
Notice: Refer to Fastener Notice .
7. Hold the strut shaft and use the J 42991 or equivalent hand tools to tighten the shaft while
verifying that the upper spring seat flats align with the
top mount.
Tighten the strut shaft to 55 N.m (41 lb ft).
8. Release the tension on the J 45400 . 9. Remove the strut assembly from the J 45400 .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13212
Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber
Shock Absorber Replacement
Shock Absorber Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the rear tire
and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and
Tires/Service and Repair) .
3. Remove the lower shock bolt and nut.
4. Remove the upper shock bolt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13213
5. Remove the shock from the vehicle.
Installation Procedure
1. Position the shock to the vehicle.
Notice: Refer to Fastener Notice .
2. Install the upper shock bolt.
Tighten the bolt to 110 N.m (81 lb ft).
3. Install the lower shock bolt and nut.
Tighten the bolt to 110 N.m (81 lb ft).
4. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Wheels and Tires/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension Strut > Page 13214
5. Lower the vehicle.
Shock Absorber Disposal
Shock Absorber Disposal
Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring
from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will
come out with extreme force which may result in personal injury.
Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the
shock absorber. Use care not to puncture the shock absorber tube with the centerpunch.
1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2.
Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely
extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill
bit. Gas or a gas/oil mixture will exhaust when the drill bit
penetrates the shock absorber. Use shop towels in order to contain the escaping oil.
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in
the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the
drill bit penetrates the
shock absorber. Use shop towels in order to contain the escaping oil.
6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally
with the holes down. Move the rod (1) in and out
of the tube (3) to completely drain the oil from the shock absorber.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair
Suspension Travel Bumper: Service and Repair
Spring Jounce Bumper Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement
Trailing Arm: Service and Repair Trailing Arm Replacement
Trailing Arm Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and
Repair) . 3. Remove the park brake cable bolt from the trailing arm and from the frame. Refer to
Parking Brake Rear Cable Replacement . 4. Remove the trailing arm bracket to body bolts. Refer
to Trailing Arm Bracket Replacement (See: Trailing Arm Bracket Replacement) .
5. Remove the trailing arm bushing to bracket nut and bolt.
6. Remove the trailing arm to knuckle bolts (1). 7. Remove the trailing arm.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement > Page 13222
Installation Procedure
1. Position the trailing arm to the vehicle.
Notice: Refer to Fastener Notice .
2. Install the trailing arm to knuckle bolts (1).
Tighten the bolts to 110 N.m (81 lb ft).
3. Position the trailing arm bracket to the trailing arm.
4. Loosely install the trailing arm bushing to bracket nut and bolt. 5. Install the trail arm bracket .
Refer to Trailing Arm Bracket Replacement (See: Trailing Arm Bracket Replacement) . 6. Tighten
the trailing arm bushing to bracket nut and bolt.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement > Page 13223
Tighten the bolt to 160 N.m (118 lb ft).
7. Install the park brake cable bolt to trailing arm and to the frame. Refer to Parking Brake Rear
Cable Replacement . 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation
(See: Wheels and Tires/Service and Repair) . 9. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement > Page 13224
Trailing Arm: Service and Repair Trailing Arm Bracket Replacement
Trailing Arm Bracket Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the park
brake cable from the trailing arm and from the frame. Refer to Parking Brake Rear Cable
Replacement .
3. Remove the trailing arm bracket to body bolts (1).
4. Remove the trailing arm bushing to bracket nut and bolt. 5. Remove the trailing arm bracket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement > Page 13225
1. Position the trailing arm bracket to the trailing arm.
2. Loosely install the trailing arm bushing to bracket nut and bolt.
3. Push upward on the trailing arm bracket and loosely install the front bolt (1).
Notice: Refer to Fastener Notice .
4. Use a drift to align the remaining trailing arm bracket bolts (1).
Tighten the trailing arm bracket to body bolts to 110 N.m (81 lb ft).
5. Tighten the trailing arm bushing to bracket nut and bolt.
Tighten the bolt to 160 N.m (118 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service
and Repair > Trailing Arm Replacement > Page 13226
6. Install the park brake cable on the trailing arm and on the frame. Refer to Parking Brake Rear
Cable Replacement . 7. Remove the support and lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Removal Procedure
1. Remove the front brake rotor. Refer to Front Brake Rotor Replacement .
2. Disconnect the wheel speed sensor electrical connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13232
3. Remove the wheel speed sensor electrical connector from the connector bracket.
4. Remove the front wheel drive shaft spindle nut. 5. Remove the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
6. Support the wheel drive shaft with heavy mechanic's wire or equivalent. 7. Remove and discard
the wheel bearing/hub mounting bolts. 8. Remove the wheel bearing/hub assembly from the
steering knuckle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13233
1. Install the wheel bearing/hub assembly to the steering knuckle.
Notice: Refer to Fastener Notice .
2. Install the wheel bearing/hub mounting bolts.
Tighten the bolts to 130 N.m (96 lb ft).
3. Install the wheel drive shaft spindle nut.
Tighten the nut to 205 N.m (151 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13234
4. Install the wheel speed sensor electrical connector to the mounting bracket, if equipped.
5. Connect the wheel speed sensor electrical connector. 6. Install the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
7. Install the front brake rotor. Refer to Front Brake Rotor Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13235
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Front Wheel Drive Shaft Spindle Nut. Tighten the nut to .....................................................................
.............................................................................................................. 205 N.m (151 lb ft).
Rear Wheel Drive Shaft Nut
Important: DO NOT re-use the wheel drive shaft spindle nut. Replace with NEW.
Hand install a new wheel drive shaft spindle nut. Tighten the nut to ...................................................
.................................................................................................................................. 125 N.m (92 lb
ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service Precautions > Technician Safety Information
Vehicle Lifting: Technician Safety Information
Vehicle Lifting Caution
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service Precautions > Technician Safety Information > Page 13245
Vehicle Lifting: Vehicle Damage Warnings
Vehicle Lifting and Jacking Notice
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service Precautions > Page 13246
Vehicle Lifting: Service and Repair
Lifting and Jacking the Vehicle
Caution: To avoid any vehicle damage, serious personal injury or death when major components
are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack
stands at the opposite end from which the components are being removed and strap the vehicle to
the hoist.
Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands
to support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure:
* Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking procedure.
* The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
* The lifting equipment or the jacking equipment must meet the operational standards of the lifting
equipment or jacking equipment's manufacturer.
* Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
* Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the
lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking
equipment, the vehicle, and/or the vehicle's contents.
Vehicle Lifting-Frame Contact Lift
Front Lift Pads
When lifting the vehicle with a frame-contact lift, place the front lift pads approximately 12.2 in (310
mm) inboard from the front pinchweld flanges.
Rear Lift Pads
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service Precautions > Page 13247
When lifting the vehicle with a frame-contact lift, place the rear lift pads 10.0 in (255 mm) inboard
from the rear pinchweld flanges.
Vehicle Jacking
Under the Center of the Rear Suspension
Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.
Supporting the Vehicle with Jackstands
Important: Place jackstands ONLY under strong and stable vehicle structures.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires >
Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires >
Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor
System - TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 13262
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 13263
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 13264
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 13265
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 13266
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13267
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service
and Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Notice: Refer to Fastener Notice .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires
> Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13268
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (Standard) (See: Tire Monitoring System/Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13274
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13275
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13276
Customer TPMS Information
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Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13277
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13278
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM
Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Page 13291
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
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Page 13292
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
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Page 13293
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
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Page 13294
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
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Page 13295
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
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Sensor > Component Information > Technical Service Bulletins > Page 13296
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
* When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service
and Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Notice: Refer to Fastener Notice .
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Sensor > Component Information > Technical Service Bulletins > Page 13297
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Tires/Service and
Repair/Removal and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire
Pressure Sensor Learn (Standard) (See: Service and Repair) .
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
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Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13302
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
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Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13303
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Customer TPMS Information
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Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13306
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 10-03-16-001 > Jul > 10 > TPMS System - Service And
Re-Learning Sensor IDs
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 13316
2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
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Procedures > Page 13317
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 13318
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
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Service Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 13319
1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 04-03-10-001F > Apr > 10 > Tires/Wheels - Tire Puncture Repair
Procedures > Page 13320
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas
in Tires
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 05-03-10-020C > Apr > 10 > Wheels/Tires - Use of Nitrogen Gas
in Tires > Page 13325
degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips
Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13330
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13331
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
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Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13332
Customer TPMS Information
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Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13333
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 09-03-16-002A > Apr > 10 > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 13334
Frequently Asked Questions
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 07-03-10-008B > Aug > 09 > Tires - Slight/Mild Edge Feathering
Information
Tires: Technical Service Bulletins Tires - Slight/Mild Edge Feathering Information
INFORMATION
Bulletin No.: 07-03-10-008B
Date: August 13, 2009
Subject: Information on Slight or Mild Tire Feathering and Recommended Practices (Normal Tire
Wear Condition)
Models:
2006-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2010 HUMMER H2,
H3 2006-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 07-03-10-008A (Section 03 - Suspension).
This bulletin provides information regarding the normal tire wear condition of slight or mild tire
feathering and recommended practices.
If a vehicle comes into a dealership with a concern of slight or mild feathering-type wear on the
tires, review with the customer their past tire rotation history. Tires should be rotated every 8,000 to
13,000 km (5,000 to 8,000 mi) for applicable vehicles with tires where a tire rotation is possible or
recommended. Refer to Corporate Bulletin Number 05-03-10-015B for information on tire rotation
for vehicles with different front/rear tire/wheel sizes.
SOME TIRE FEATHERING IS A NORMAL PART OF TIRE WEAR AND THROUGH PROPER
TIRE ROTATION AND INFLATION, THIS TIRE WEAR CAN BE MINIMIZED AND TIRE LIFE
MAXIMIZED.
If the customer has not rotated the tires within the last 8,000 to 13,000 km (5,000 to 8,000 mi), a
tire rotation in the modified X-pattern is necessary to clean-up the feathering, rather than placing
the vehicle on the alignment machine.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > 00-00-90-002J > Jan > 09 > Tires - Correct Inflation Pressure
Information
Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information
INFORMATION
Bulletin No.: 00-00-90-002J
Date: January 28, 2009
Subject: Information on Proper Tire Pressure
Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X
Supercede:
This bulletin is being revised to add model years and clarify additional information. Please discard
Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information).
Important:
^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and
no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure
will be rejected.
^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on
the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI).
Recommended inflation pressure is not the pressure printed on tire sidewall.
^ Tires may be over-inflated from the assembly plant due to the mounting process.
^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure change.
^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires
with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a
low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which
specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window
of "usable" pressure values and the warning will be more sensitive to outside temperature changes
during the colder months. As with other cold temperature/tire pressure issues, there is nothing
wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and
set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard.
Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars
and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s
tire placard during PDI.
Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure.
The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct
pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The
tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear
compartment lid.
Tip
^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire
pressure increase.
^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more
than 1.6 km (1 mi).
^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for
the low external temperature by adding additional air to the tire during PDI.
^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an
exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating
temperature), the tire pressure should be reset to placard pressure at the cold temperature.
^ The TPM system will work correctly with nitrogen in tires.
^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other
commercially available sealants.
Important:
^ Do not use the tire pressure indicated on the tire itself as a guide.
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Information > Page 13343
^ Always inspect and adjust the pressure when the tires are cold.
^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire
rotation.
Improper tire inflation may result in any or all of the following conditions:
^ Premature tire wear
^ Harsh ride
^ Excessive road noise
^ Poor handling
^ Reduced fuel economy
^ Low Tire Pressure Monitor (TPM) Light ON
^ Low Tire Pressure Message on the Drivers Information Center (DIC)
Disclaimer
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Service Bulletins > Technical Service Bulletins for Tires: > Page 13344
Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
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Service Bulletins > Technical Service Bulletins for Tires: > Page 13345
Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires
INFORMATION
Bulletin No.: 05-03-10-020C
Date: April 27, 2010
Subject: Use of Nitrogen Gas in Tires
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-03-10-020B (Section 03 - Suspension).
GM's Position on the Use of Nitrogen Gas in Tires
General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect
the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to
continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with
compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical
benefits, practical limitations, and the robust design of GM original equipment TPC tires, the
realized benefits to our customer of inflating their tires with purified nitrogen are expected to be
minimal.
The Promise of Nitrogen: Under Controlled Conditions
Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. The following benefits under controlled conditions are attributed to nitrogen gas and its
unique properties:
- A reduction in the expected loss of Tire Pressure over time.
- A reduction in the variance of Tire Pressures with temperature changes due to reduction of water
vapor concentration.
- A reduction of long term rubber degradation due to a decrease in oxygen concentrations.
Important These are obtainable performance improvements when relatively pure nitrogen gas is
used to inflate tires under controlled conditions.
The Promise of Nitrogen: Real World Use
Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the
molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration)
has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are
larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing.
The actual obtainable benefits of nitrogen vary, based on the physical construction and the
materials used in the manufacturing of the tire being inflated.
Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has
demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the
inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be
reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are
required to begin the normal oxidation process. Even slight contamination of the tire inflation gas
with compressed atmospheric air during normal inflation pressure maintenance, may negate the
benefits of using nitrogen.
GM Tire Quality, Technology and Focus of Importance
Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria)
specification system, which includes specific requirements that ensure robust tire performance
under normal usage. General Motors works with tire suppliers to design and manufacture original
equipment tires for GM vehicles. The GM TPC addresses required performance with respect to
both inflation pressure retention, and endurance properties for original equipment tires. The
inflation pressure retention requirements address availability of oxygen and oxidation concerns,
while endurance requirements ensure the mechanical structure of the tire has sufficient strength.
This combination has provided our customers with tires that maintain their structural integrity
throughout their useful treadlife under normal operating conditions.
Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the
correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in
many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear,
and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation
pressure maintenance is necessary for the tire to support the load imposed by the vehicle without
excessive structural
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degradation.
Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure
maintenance of tires is critical for overall tire, and ultimately, vehicle performance.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Technical Service Bulletins for Tires: > Page 13347
Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures
INFORMATION
Bulletin No.: 04-03-10-001F
Date: April 27, 2010
Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 04-03-10-001E (Section 03 - Suspension).
This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in
the tread area only. The tire manufacturer must be contacted for its individual repair policy and
whether or not the speed rating is retained after repair.
Caution
- Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
- Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
- NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
- NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important
- NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth).
- NEVER repair tires with a tread puncture larger than 6.35 mm (1/4").
- NEVER substitute an inner tube for a permissible or non-permissible repair.
- NEVER perform an outside-in tire repair (plug only, on the wheel).
- Every tire must be removed from the wheel for proper inspection and repair.
- Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
- Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair.
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2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent
air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
Clean the Injury Channel
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Service Bulletins > Technical Service Bulletins for Tires: > Page 13349
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this
step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug
per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
Important Do not install the repair unit in this step.
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1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
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1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads
excessively).
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
2. Consult your repair material supplier for the proper stitching tool.
Safety Cage
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Service Bulletins > Technical Service Bulletins for Tires: > Page 13352
Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may
require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be
used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - OFF Vehicle.
For additional tire puncture repair information, contact:
Rubber Manufacturers Association (RMA)
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information >
Description and Operation > Tread Wear Indicators Description
Tires: Description and Operation Tread Wear Indicators Description
Tread Wear Indicators Description
Tread Wear Indicators Description
The original equipment tires have tread wear indicators that show when you should replace the
tires.
The location of these indicators are at 60 degree intervals around the outer diameter of the tire.
The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm
(2/32 in).
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Description and Operation > Tread Wear Indicators Description > Page 13355
Tires: Description and Operation Tire Inflation Description
Tire Inflation Description
When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and
tires are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures,
or under-inflated tires, can cause the following conditions:
* Vehicle handling concerns
* Poor fuel economy
* Shortened tire life
* Tire overloading
Inspect the tire pressure when the following conditions apply:
* The vehicle has been sitting at least 3 hours.
* The vehicle has not been driven for more than 1.6 km (1 mi).
* The tires are cool.
Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications
on the tire label. Install the valve caps or the extensions on the valves. The caps or the extensions
keep out dust and water.
The kilopascal (kPa) is the metric term for pressure. The tire pressure may be printed in both
kilopascal (kPa) and psi. One psi equals 6.9 kPa.
Tires with a higher than recommended pressure can cause the following conditions:
* A hard ride
* Tire bruising
* Rapid tread wear at the center of the tire
Tires with a lower than recommended pressure can cause the following conditions:
* A tire squeal on turns
* Hard steering
* Rapid wear and uneven wear on the edge of the tread
* Tire rim bruises and tire rim rupture
* Tire cord breakage
* High tire temperatures
* Reduced vehicle handling
* High fuel consumption
* Soft riding
Unequal pressure on the same axle can cause the following conditions:
* Uneven braking
* Steering lead
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* Reduced vehicle handling
Refer to the Tire Placard for specific tire and wheel applications and tire pressures.
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Tires: Description and Operation All Seasons Tires Description
All Seasons Tires Description
All Seasons Tires Description
Most Saturn vehicles are equipped with steel belted all-season radial tires as standard equipment.
These tires qualify as snow tires, with a higher than average rating for snow traction than the
non-all season radial tires previously used. Other performance areas, such as wet traction, rolling
resistance, tread life, and air retention, are also improved. This is done by improvements in both
tread design and tread compounds. These tires are identified by an M + S molded in the tire side
wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification
number.
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Tires: Description and Operation P-Metric Sized Tires Description
P-Metric Sized Tires Description
P-Metric Sized Tires Description
Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement
tires should be of the same tire performance criteria TPC specification number including the same
size, the same load range, and the same construction as those originally installed on the vehicle.
Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best
recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. The
above illustration may not correspond with your vehicle, but is meant as an example.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service
and Repair > Procedures
Tires: Procedures
Tire Repair
Tire Repair
Caution:
* Tire changing can be dangerous and should be done by trained professionals using proper tools
and procedures. Always read and understand any manufacturer's warnings contained in their
customers literature or molded into the tire sidewall.
* Serious eye and ear injury may result from not wearing adequate eye and ear protection while
repairing tires.
* NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads.
* NEVER stand, lean or reach over the assembly during inflation.
Repairable area on a radial tire.
Important:
* NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth.
* NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in).
* NEVER substitute an inner tube for a permissible or non-permissible repair.
* NEVER perform an outside-in tire repair (plug only, on the wheel).
* Every tire must be removed from the wheel for proper inspection and repair.
* Regardless of the type of repair used, the repair must seal the inner liner and fill the injury.
* Consult with repair material supplier/manufacturer for repair unit application procedures and
repair tools/repair material recommendations.
Three basic steps for tire puncture repair:
1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep
moisture out. 3. Seal the inner liner with a repair unit to prevent air loss.
External Inspection
1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak
by using a water and soap solution. Mark the
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injured area and totally deflate the tire by removing the valve core.
2. Demount the tire from the wheel and place the tire on a well-lighted spreader.
Internal Inspection
1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs
of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4.
Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5.
Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should
not be repaired.
Cleaning
1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a
scraper. This step serves to remove dirt and mold
lubricants to insure proper adhesion and non-contamination of the buffing tool.
2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow
guidelines for handling and disposal.
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Clean the Injury Channel
1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside
of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to
prevent damage to the repair unit. 3. Consult your repair material supplier for recommended
reaming tool(s).
Fill the Injury
1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent
moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this
step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per
repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just
above the inside tire surface.
3. Consult your repair material supplier for proper repair material selection.
Repair Unit Selection
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Important: Do not install the repair unit in this step.
1. Center the repair unit over the injury as a reference and outline an area larger than the unit so
that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap
previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit
selection.
Buffing
1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and
evenly with a low speed buffing tool using a fine
wire brush or gritted rasp.
2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the
inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult
your repair material supplier for a proper buffing tool.
Cementing
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Apply chemical cement according to the repair material manufacturer's procedures.
Repair Unit Application
The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads
excessively.
Two-Piece Plug and Repair Units
1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over
the injury and stitch down thoroughly with the stitching tool, working from the center out.
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3. Being careful not to stretch the plug material, cut the plug flush with the outer tread.
Combination Repair/Plug Units
1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2.
Follow the repair material manufacturer's recommendations for further installation instructions.
Consult your repair material supplier for the proper stitching tool.
Safety Cage
Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire
safety cage must be used. Consult the tire manufacturer for its individual repair policy.
Final Inspection
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1. After remounting and inflating the tire, check both beads, the repair and the valve with a water
and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be
demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel
Assembly Balancing - Off Vehicle .
For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA)
1400 K Street, N.W., Suite 900 Washington, DC 20005-2403
Tire Rotation
Tire Rotation
Rotate the tires and wheels at frequent intervals to equalize wear. Refer to Maintenance Schedule
(North American Emissions) . In addition to scheduled rotation, rotate the tire and wheel whenever
uneven tire wear is noticed.
Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in
non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes
regular rotation especially necessary.
Refer to Tire and Wheel Removal and Installation (See: Service and Repair) .
Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then, set
the tire pressure.
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Tires: Removal and Replacement
Tire Mounting and Dismounting
Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons
alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could
result.
Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing
equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear
coating to peel from the wheel.
Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of
improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air
to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire
changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage
may result in vibration and/or shimmy, and under severe usage lead to wheel cracking.
1. Deflate the tire completely.
Important: Rim-clamp European-type tire changers are recommended.
2. Use the tire changer in order to remove the tire from the wheel. 3. Use a wire brush or coarse
steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats.
Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or
corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound
can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration.
4. Apply an approved Lubricant to the tire bead and the wheel rim. 5. Use the tire changer in order
to install the tire to the wheel.
Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may
break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when
inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads,
deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause
serious personal injury.
6. Inflate the tire to the proper air pressure. 7. Ensure that the locating rings are visible on both
sides of the tire in order to verify that the tire bead is fully seated on the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV)
Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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(RFV) > Page 13376
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
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(RFV) > Page 13377
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation
(RFV) > Page 13378
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast
Aluminum Wheels
Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
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Aluminum Wheels > Page 13383
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON
Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 13388
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
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Flat/Warning Light ON > Page 13389
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
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Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes
Flat/Warning Light ON > Page 13390
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion > Page 13396
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
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Wheel Staining/Pitting/Corrosion > Page 13397
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
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Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome
Wheel Staining/Pitting/Corrosion > Page 13398
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
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longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
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Procedures/Precautions > Page 13408
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
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Procedures/Precautions > Page 13409
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV)
Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV)
INFORMATION
Bulletin No.: 00-03-10-006F
Date: May 04, 2010
Subject: Information on Tire Radial Force Variation (RFV)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009
and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION
Supercede: This bulletin is being revised to considerably expand the available information on
Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin
Number 00-03-10-006E (Section 03 - Suspension).
Important
- Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven
a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin
Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires.
- Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel
assemblies for each vehicle.
The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation
measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable
tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force
variation is highway speed shake on smooth roads.
Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out
of round and tire force variation. These three conditions are not necessarily related. All three
conditions must be addressed.
Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle,
two plane dynamic wheel balancers are readily available and can accurately correct any
imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer,
and proper balance weights, are all factors required for a quality balance. However, a perfectly
balanced tire/wheel assembly can still be "oval shaped" and cause a vibration.
Before balancing, perform the following procedures.
Tire and Wheel Diagnosis
1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are
centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while
shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick.
3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and
correct as necessary:
- Missing balance weights
- Bent rim flange
- Irregular tire wear
- Incomplete bead seating
- Tire irregularities (including pressure settings)
- Mud/ice build-up in wheel
- Stones in the tire tread
- Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to
diagnosing a smooth road shake condition.
4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a
sufficient distance on a known, smooth road
surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes
are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section
of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration
as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order
(one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high
enough in frequency that most humans can start to hear them at highway speeds, but are too high
to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment.
If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a
throbbing), chances are good that the vehicle could have driveline vibration. This type
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Radial Force Variation (RFV) > Page 13414
of vibration is normally felt more in the "seat of the pants" than the steering wheel.
5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found
at the end of this bulletin. This should be done
after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to
eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency
is prior to vehicle service and documents the amount of improvement occurring as the result of the
various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required.
A copy of the completed worksheet must be saved with the R.O. and a copy included with any
parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically
indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number
08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if
this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away
and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration
may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if
vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire
flat-spotting can be ruled out as the cause for vibration.
6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle
being parked for long periods of time and that the
nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information
on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment
Tires.
7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel
assembly on a known, calibrated, off-car dynamic
balancer.Make sure the mounting surface of the wheel and the surface of the balancer are
absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and
always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is
not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim
flange, remove all balance weights and rebalance to as close to zero as possible. If you can see
the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the
wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First
order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or
hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough,
it can be seen.
If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and
force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700
can address both (it is also a wheel balancer).
Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will
produce in one revolution under a constant load. Radial force variation is what the vehicle feels
because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not
under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel
assembly runout be within specification.
Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures
radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV
measurement at this point. To isolate the wheel, its runout must be measured. This can be easily
done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout
specification, the tire's RFV can then be addressed.
After measuring the tire/wheel assembly under load, and the wheel alone, the machine then
calculates (predicts) the radial force variation of the tire. However, because this is a prediction that
can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in
tire production, this type of service equipment should NOT be used to audit new tires. Rather, it
should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel
assembly.
Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of
finding the low point of the wheel (for runout) and the high point of the tire (for radial force
variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly
force variation.
The machine will simplify this process into easy steps. The following assembly radial force variation
numbers should be used as a guide:
When measuring RFV and match mounting tires perform the following steps.
Measuring Wheel Runout and Assembly Radial Force Variation
Important The completed worksheet at the end of this bulletin must be attached to the hard copy of
the repair order.
- Measure radial force variation and radial runout.
- If a road force/balancing machine is used, record the radial force variation (RFV) on the
worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the
front left corner. If the machine is not available and the EVA data suggests there is an issue, swap
the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem
still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those
tires onto the subject vehicle.
- If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the
worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040
in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive
customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to
have the lowest runout assembly to the front left corner. If the machine is not available and the
EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the
back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do
not exhibit the same frequency and swap those tires
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV) > Page 13415
onto the subject vehicle.
- After match mounting, the tire/wheel assembly must be rebalanced.
If match mounting tires to in-spec wheels produces assembly values higher than these, tire
replacement may be necessary. Replacing tires at lower values will probably mean good tires are
being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect
force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring.
Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to
measuring.
Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are
more sensitive, and may require lower levels. Also, there are other tire parameters that equipment
such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be
contacted for further instructions.
Important
- When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's
center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are
secondary. Usually a back cone method to the machine should be used. For added accuracy and
repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This
system is offered by all balancer manufacturers in GM's dealer program.
- Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT
recommended, and may void the tire warranty. However, tires may have been ground by the tire
company as part of their tire manufacturing process. This is a legitimate procedure.
Steering Wheel Shake Worksheet
When diagnosing vibration concerns, use the following worksheet in conjunction with the
appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire
Radial Force Variation (RFV) > Page 13416
Refer to the appropriate section of SI for specifications and repair procedures that are related to the
vibration concern.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low
Tire/Leaking Cast Aluminum Wheels
Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels
TECHNICAL
Bulletin No.: 05-03-10-003F
Date: April 27, 2010
Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant)
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels
Supercede: This bulletin is being revised to update the model years and the bulletin reference
information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension).
Condition
Some customers may comment on a low tire pressure condition.
Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel.
Cause
Porosity in the cast aluminum wheel may be the cause.
Notice
This bulletin specifically addresses issues related to the wheel casting that may result in an air
leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin
Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light
Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat).
Correction
1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service
procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the
tire/wheel assembly in a water bath, or use a spray bottle with soap
and water to locate the specific leak location.
Important
- If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim),
the wheel should be replaced.
- If two or more leaks are located on one wheel, the wheel should be replaced.
3. If air bubbles are observed, mark the location.
- If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks.
- If the leak is located on the aluminum wheel area, continue with the next step.
4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the
wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove
the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the
INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose
cleaner, such as 3M(R) General Purpose
Adhesive Cleaner, P/N 08984, or equivalent.
8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use
88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry.
Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging
the repair area may result in an air leak.
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low
Tire/Leaking Cast Aluminum Wheels > Page 13421
10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire
Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on
the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and
inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the
tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire
and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty
one tube of adhesive/sealant per wheel repair.
For vehicles repaired under warranty, use:
One leak repair per wheel.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON
Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON
TECHNICAL
Bulletin No.: 08-03-10-006C
Date: April 27, 2010
Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated,
Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat)
Models:
2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-03-10-006B (Section 03 - Suspension).
Condition
Some customers may comment on a tire that slowly loses air pressure over a period of days or
weeks.
Cause
Abrasive elements in the environment may intrude between the tire and wheel at the bead seat.
There is always some relative motion between the tire and wheel (when the vehicle is driven) and
this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear
continues, there may also be intrusion at the tire/wheel interface by corrosive media from the
environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may
appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be
visible until the tire is dismounted from the wheel.
Notice
This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in
an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please
refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum
Wheels (Repair with Adhesive Sealant)
Correction
In most cases, this type of air loss can be corrected by following the procedure below.
Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to
repair the wheel with the procedure below.
Notice
The repair is no longer advised or applicable for chromed aluminum wheels.
1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and
Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to
be around the bead seat of the wheel, dismount the tire to examine
the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat
Corrosion
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 13426
Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel
flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for
additional information on possible wheel porosity issues.
3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a
rough or uneven surface that is difficult for the tire to
maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel
that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion
4. If corrosion is found on the wheel bead seat, measure the affected area as shown below.
- For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of
repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
- For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area
of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these
dimensions, the wheel should be replaced.
5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the
corrosion and any flaking paint. You should
remove the corrosion back far enough until you reach material that is stable and firmly bonded to
the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges
that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired
surface.
Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be
visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not
visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend
to the visible surfaces on the FACE of the wheel, that wheel must be replaced.
Important Remove ONLY the material required to eliminate the corrosion from the bead seating
surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as
smooth and level as possible.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 13427
Acceptably Prepared (Cleaned-Up) Wheel Surface
6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially
available tire sealant such as Patch Brand Bead
Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will
permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this
sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat
7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel
Removal and Installation in SI.
Parts Information
Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at
www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire
Slowly Goes Flat/Warning Light ON > Page 13428
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome
Wheel Brake Dust Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion
INFORMATION
Bulletin No.: 00-03-10-002F
Date: April 21, 2011
Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum
Wheels
Models:
2012 and Prior GM Cars and Trucks
Supercede: This bulletin is being revised to update model years, suggest additional restorative
products and add additional corrosion information. Please discard Corporate Bulletin Number
00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the
customer.
What is Chemical Staining of Chrome Wheels? Figure 1
Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an
example). These stains are frequently milky, black, or greenish in appearance. They result from
using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient
to clean wheels.
If the customer insists on using a wheel cleaner they should only use one that specifically states
that it is safe for chromed wheels and does not contain anything in the following list. (Dealers
should also survey any products they use during prep or normal cleaning of stock units for these
chemicals.)
- Ammonium Bifluoride (fluoride source for dissolution of chrome)
- Hydrofluoric Acid (directly dissolves chrome)
- Hydrochloric Acid (directly dissolves chrome)
- Sodium Dodecylbenzenesulfonic Acid
- Sulfamic Acid
- Phosphoric Acid
- Hydroxyacetic Acid
Notice
Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most
customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal.
Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the
paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car
warranty. Soap and water applied with a soft brush is usually all that is required to clean the
calipers.
Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean,
clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts,
lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to
the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the
damage around and under the wheel weight where the cleaner was incompletely flushed away.
Notice
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 13438
Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome
wheels (or any wheels).
If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be
avoided.
For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and
Instructions below.
Warranty of Stained Chrome Wheels
Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome
wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were
returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be
charged back to the dealership. To assist the customer, refer to Customer Assistance and
Instructions below.
Pitting or Spotted Appearance of Chrome Wheels Figure 2
A second type or staining or finish disturbance may result from road chemicals, such as calcium
chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to
Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be
uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels
should be washed with mild soap and water and thoroughly rinsed as soon as conveniently
possible.
Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can
also stain chrome wheels. The staining will look like small pitting. This staining will usually be on
the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward
direction while being splashed by the road chemical. If a vehicle must be operated under such
conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed
as soon as conveniently possible.
Warranty of Pitted or Spotted Chrome Wheels
Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time.
Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish
and may cause damage if the wheels are not kept clean.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean if they are operating the vehicle in an area that
applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior
approval by the District Manager - Customer Care and Service Process (DM-CCSP).
"Stardust" Corrosion of Chrome Wheels Figure 3
A third type of finish disturbance results from prolonged exposure to brake dust and resultant
penetration of brake dust through the chrome. As brakes are applied hot particles of brake material
are thrown off and tend to be forced through the leading edge of the wheel spoke windows by
airflow. These
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Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 13439
hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed
to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the
chrome leaving a pit or small blister in the chrome.
Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and
Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up
or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars
Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be
waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax
#M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake
dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may
be used. It will clean and shine the chrome and leave behind a wax coating that may help protect
the finish.
Warranty of Stardust Corroded Chrome Wheels
Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be
replaced one time.
Important Notify the customer that this is a one time replacement. Please stress to the customer
the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust
build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care
and Service Process (DM-CCSP).
Customer Assistance and Instructions
GM has looked for ways customers may improve the appearance of wheels damaged by acidic
cleaners. The following product and procedure has been found to dramatically improve the
appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the
following:
Notice
THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN
EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE
APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL
REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED
INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER,
EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS
EXACTLY.
1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce
wheel staining. Flood all areas of the wheel with water
to rinse.
2. Dry the wheels completely.
Notice Begin with a small section of the wheel and with light pressure buff off polish and examine
results. ONLY apply and rub with sufficient force and time to remove enough staining that you are
satisfied with the results. Some wheels may be stained to the extent that you may only achieve a
50% improvement while others may be able to be restored to the original lustre. IN ALL CASES,
only apply until the results are satisfactory.
3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the
polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the
towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If
continued applications fail to improve the appearance
further discontinue use.
This procedure will improve the appearance of the wheels and may, with repeated applications,
restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above
procedure may marginally improve the condition but will not restore the finish or remove the pitting.
In this type of staining the wheel finish has actually been removed in spots and no manner of
cleaning will restore the finish.
†*We believe this source and their products to be reliable. There may be additional manufacturers
of such products/materials. General Motors does not endorse, indicate any preference for or
assume any responsibility for the products or material from this firm or for any such items that may
be available from other sources.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel
Staining/Pitting/Corrosion > Page 13440
*This product is currently available from 3M. To obtain information for your local retail location
please call 3M at 1-888-364-3577.
**This product is currently available from Meguiars (Canada). To obtain information for your local
retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com.
^ This product is currently available from Tri-Peek International. To obtain information for your local
retail location please call Tri-Peek at
1-877-615-4272 or at www.tripeek.com.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels
Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels
INFORMATION
Bulletin No.: 99-08-51-007E
Date: March 17, 2011
Subject: Refinishing Aluminum Wheels
Models:
2012 and Prior GM Passenger Cars and Trucks
Supercede: This bulletin is being revised to add additional model years. Please discard Corporate
Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories).
This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not
endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic
refinishing of the wheel's coatings, using recommended procedures, is allowed.
Evaluating Damage
In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion,
scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be
sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the
wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been
refinished by an outside company must be returned to the same vehicle. The Dealer must record
the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to
Refinisher's Responsibility - Outside Company later in this bulletin.
Aluminum Wheel Refinishing Recommendations
- Chrome-plated aluminum wheels Re-plating these wheels is not recommended.
- Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the
clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be
performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later
in this bulletin.
- Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat
procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original
coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum
Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel.
- Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them.
In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is
possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel
should be resurfaced by using a sanding process rather than a machining process. This allows the
least amount of material to be removed.
Important Do not use any re-machining process that removes aluminum. This could affect the
dimensions and function of the wheel.
Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will
better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM
recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle
SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using
any of the painting options, it is recommended that all four wheels be refinished in order to maintain
color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures
and product recommendations.
Refinisher's Responsibility - Outside Company
Important Some outside companies are offering wheel refinishing services. Such refinished wheels
will be permanently marked by the refinisher and are warranted by the refinisher. Any process that
re-machines or otherwise re-manufactures the wheel should not be used.
A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent.
Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is
allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to
assure that the same wheel is returned. A plastic media blast may be used for clean up of the
wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed.
Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed.
Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel
mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel
and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the
new vehicle warranty, whichever is
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 13445
longer.
Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact
surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut
torque.
When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to
reduce the chance of future cosmetic damage.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions
Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions
INFORMATION
Bulletin No.: 06-03-10-010A
Date: June 09, 2010
Subject: Information on Proper Wheel Changing Procedures and Cautions
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab
9-7X 2005-2009 Saturn Vehicles
Attention:
Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel
Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and
reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel
installation. Always refer to SI for wheel lug nut torque specifications and complete jacking
instructions for safe wheel changing.
Supercede: This bulletin is being revised to include the 2011 model year and update the available
special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension).
Frequency of Wheel Changes - Marketplace Driven
Just a few years ago, the increasing longevity of tires along with greater resistance to punctures
had greatly reduced the number of times wheels were removed to basically required tire rotation
intervals. Today with the booming business in accessory wheels/special application tires (such as
winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more
than ever. With this increased activity, it opens up more of a chance for error on the part of the
technician. This bulletin will review a few of the common concerns and mistakes to make yourself
aware of.
Proper Servicing Starts With the Right Tools
The following tools have been made available to assist in proper wheel and tire removal and
installation.
- J 41013 Rotor Resurfacing Kit (or equivalent)
- J 42450-A Wheel Hub Resurfacing Kit (or equivalent)
Corroded Surfaces
One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle.
Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened
wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed
away from water splash. This action may result in clearance at the mating surface of the wheel and
an under-torqued condition.
Caution
Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or
brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting
surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is
moving, possibly resulting in a loss of control or personal injury.
Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If
corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding
pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating
surface.
The J 41013 (or equivalent) can be used to clean the following surfaces:
- The hub mounting surface
- The brake rotor mounting surface
- The wheel mounting surface
Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub.
Lubricants, Grease and Fluids
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 13450
Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in
removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to
installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper
readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY.
Notice
Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or
drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to
clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light
coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel
pilot hole to prevent wheel seizure to the axle or bearing hub.
Wheel Stud and Lug Nut Damage
Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse.
You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not
retain properly, yet give the impression of fully tightening. Always inspect and replace any
component suspected of damage.
Tip
Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged
BEFORE tightening the nut.
Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side
of the tire is pointing in the direction of forward rotation.
Wheel Nut Tightening and Torque
Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid
additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown
for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in
order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off
center resulting in vibration.
The Most Important Service You Provide
While the above information is well known, and wheel removal so common, technicians run the risk
of becoming complacent on this very important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing
Procedures/Precautions > Page 13451
service operation. A simple distraction or time constraint that rushes the job may result in personal
injury if the greatest of care is not exercised. Make it a habit to double check your work and to
always side with caution when installing wheels.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome
Wheel Brake Dust Accumulation/Pitting
Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting
Bulletin No.: 04-03-10-012B
Date: February 01, 2008
INFORMATION
Subject: Pitting and Brake Dust on Chrome wheels
Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior
HUMMER H2, H3 2005-2008 Saab 9-7X
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
04-03-10-012A (Section 03 - Suspension).
Analysis of Returned Wheels
Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have
recently been evaluated. This condition is usually most severe in the vent (or window) area of the
front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the
wheel. The longer this accumulation builds up, the more difficult it is to remove.
Cleaning the Wheels
In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care
Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should
confine your treatment to the areas of the wheel that show evidence of the brake dust build-up.
This product is only for use on chromed steel or chromed aluminum wheels.
Parts Information
Warranty Information
Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited
Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Description and Operation > Replacement Wheels Description
Wheels: Description and Operation Replacement Wheels Description
Replacement Wheels Description
Replace the wheel if any of the following conditions exist:
* The wheel exhibits excessive runout
* The wheel is bent
* The wheel is cracked
* The wheel is severely rusted
* The wheel is severely corroded
Important: Air leaks caused by porosity on aluminum wheels are repairable.
* The wheel leaks air
Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s),
install only new Saturn original equipment parts. Installation of used parts or non-Saturn original
equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and
loss of vehicle control resulting in personal injury.
Notice: The use of non-Saturn original equipment wheels may cause:
* Damage to the wheel bearing, the wheel fasteners and the wheel
* Tire damage caused by the modified clearance to the adjacent vehicle components
* Adverse vehicle steering stability caused by the modified scrub radius
* Damage to the vehicle caused by the modified ground clearance
* Speedometer and odometer inaccuracy
Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of
the following conditions exist:
* The wheel has elongated bolt holes.
* The wheel/nuts, or bolts if applicable, loosen repeatedly.
Steel wheel identification is stamped into the wheel near the valve stem.
Aluminum wheel identification is cast into the inboard side of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information >
Description and Operation > Replacement Wheels Description > Page 13458
Wheels: Description and Operation Steel Wheel Repair Description
Steel Wheel Repair Description
Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from
striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and
uncontrolled heating from welding affects the properties of the material.
Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed
ratings are greatly reduced.
If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection
Wheel Bearing: Testing and Inspection
Wheel Bearings Diagnosis
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Front Wheel Bearing and Hub Replacement
Removal Procedure
1. Remove the front brake rotor. Refer to Front Brake Rotor Replacement .
2. Disconnect the wheel speed sensor electrical connector, if equipped.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13464
3. Remove the wheel speed sensor electrical connector from the connector bracket.
4. Remove the front wheel drive shaft spindle nut. 5. Remove the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
6. Support the wheel drive shaft with heavy mechanic's wire or equivalent. 7. Remove and discard
the wheel bearing/hub mounting bolts. 8. Remove the wheel bearing/hub assembly from the
steering knuckle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13465
1. Install the wheel bearing/hub assembly to the steering knuckle.
Notice: Refer to Fastener Notice .
2. Install the wheel bearing/hub mounting bolts.
Tighten the bolts to 130 N.m (96 lb ft).
3. Install the wheel drive shaft spindle nut.
Tighten the nut to 205 N.m (151 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13466
4. Install the wheel speed sensor electrical connector to the mounting bracket, if equipped.
5. Connect the wheel speed sensor electrical connector. 6. Install the speed sensor. Refer to Front
Wheel Speed Sensor Replacement .
7. Install the front brake rotor. Refer to Front Brake Rotor Replacement .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension > Page 13467
Wheel Bearing: Service and Repair Rear Suspension
Rear Wheel Bearing and Hub Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component
Information > Specifications
Axle Nut: Specifications
Front Wheel Drive Shaft Spindle Nut. Tighten the nut to .....................................................................
.............................................................................................................. 205 N.m (151 lb ft).
Rear Wheel Drive Shaft Nut
Important: DO NOT re-use the wheel drive shaft spindle nut. Replace with NEW.
Hand install a new wheel drive shaft spindle nut. Tighten the nut to ...................................................
.................................................................................................................................. 125 N.m (92 lb
ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Specifications
Wheel Fastener: Specifications
Wheel Nut Hand start the wheel nuts.
Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to
avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification.
Using the J 39544-KIT (proper size torque stick), tighten the wheel nuts in sequence. Tighten to .....
..............................................................................................................................................................
............................. 140 Nm (100 lb ft.)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Specifications > Page 13475
Wheel Fastener: Description and Operation
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
* The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x
1.5.
* M = Metric
* 12 = Diameter in millimeters
* 1.5 = Millimeters gap per thread
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the wheel bearing/hub assembly. Refer to Front Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Front
Suspension) .
4. Using the J 43631 , press out the wheel stud from the wheel bearing/hub assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 13478
Installation Procedure
1. Install the wheel stud to the wheel bearing/hub assembly from the bearing side of the hub flange.
2. Place flat washers over the wheel stud being installer. 3. Install the wheel nut or a hex head nut
to the wheel stud. 4. Gradually tighten the nut in order to draw the stud into the hub flange until the
head of the wheel stud is fully seated against the hub flange. 5. Remove the nut and flat washers.
6. Install the wheel bearing/hub assembly to the steering knuckle. Refer to Front Wheel Bearing
and Hub Replacement (See: Wheel Bearing/Service
and Repair/Front Suspension) .
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 8. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 13479
Wheel Fastener: Service and Repair Rear Suspension
Wheel Stud Replacement
Tools Required
J 43631 Ball Joint Remover
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the tire and
wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3.
Remove the wheel bearing/hub replacement. Refer to Rear Wheel Bearing and Hub Replacement
(See: Wheel Bearing/Service and Repair/Rear
Suspension) .
4. Using the J 43631 , press out the wheel stud from the wheel bearing/hub assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information
> Service and Repair > Front Suspension > Page 13480
Installation Procedure
1. Install the wheel stud to the wheel bearing/hub assembly from the bearing side of the hub flange.
2. Place flat washers over the wheel stud being installed. 3. Install the wheel nut or a hex head nut
to the wheel stud. 4. Gradually tighten the nut in order to draw the stud into the hub flange until the
head of the wheel stud is fully seated against the hub flange. 5. Remove the nut and flat washers.
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See:
Service and Repair) . 7. Lower the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations
Air Door Actuator / Motor: Locations
Instrument Panel/Center Console Component Views
Front HVAC Module Components
1 - Recirculation Actuator 2 - HVAC Blower Motor 3 - Blower Motor Control Processor 4 - Air
Temperature Actuator 5 - Mode Actuator 6 - Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations > Page 13486
Air Door Actuator / Motor: Diagrams
Component Connector End Views
Air Temperature Actuator
Mode Actuator
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Locations > Page 13487
Recirculation Actuator
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement
Air Door Actuator / Motor: Service and Repair Air Temperature Actuator Replacement
Air Temperature Actuator Replacement
Removal Procedure
1. Remove the instrument panel compartment. 2. Disconnect the electrical connector from the air
temperature actuator. 3. Remove the air temperature actuator screws from the HVAC module. 4.
Remove the air temperature actuator from the HVAC module.
Installation Procedure
1. Align the air temperature actuator with the door shaft and rotate into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13490
Notice: Refer to Fastener Notice.
2. Install the air temperature actuator screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the air temperature actuator.
Important: Any time an actuator or the HVAC control module is replaced, the HVAC control module
must be calibrated to ensure proper air distribution.
4. Calibrate the actuators. Refer to Actuator Recalibration. See: Testing and
Inspection/Programming and Relearning 5. Cycle the ignition and verify proper operation. 6. Install
the instrument panel compartment.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13491
Air Door Actuator / Motor: Service and Repair Mode Actuator Replacement
Mode Actuator Replacement
Removal Procedure
1. Remove the left side insulator/closeout panel. 2. Remove the communication interface module, if
equipped. 3. Disconnect the electrical connector from the mode actuator. 4. Remove the mode
actuator screws from the evaporator case assembly. 5. Remove the mode actuator from the
evaporator case assembly.
Installation Procedure
1. Install the mode actuator to the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13492
Notice: Refer to Fastener Notice.
2. Install the mode actuator screws to the evaporator case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the mode actuator. 4. Install the communication interface
module, if equipped. 5. Install the left side insulator/closeout panel.
Important: Any time a mode actuator or the HVAC control module is replaced, the HVAC control
module must be calibrated to ensure proper air distribution.
6. Calibrate the actuators. Refer to Actuator Recalibration. See: Testing and
Inspection/Programming and Relearning 7. Cycle the ignition and verify proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13493
Air Door Actuator / Motor: Service and Repair Mode Control Cam Replacement
Mode Control Cam Replacement
Removal Procedure
1. Remove the left side insulator/closeout panel. 2. Remove the communication interface module, if
equipped. 3. Disconnect the electrical connector from the mode actuator. 4. Remove the mode
actuator screws from the evaporator case assembly. 5. Remove the mode actuator from the
evaporator case assembly.
6. Remove the screws retaining the mode cam bracket (1) to the evaporator case assembly. 7.
Remove the mode cam bracket (1) from the evaporator case assembly. 8. Remove the mode cam
(2) and the mode cam levers (3) from the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13494
Installation Procedure
1. Install the mode cam levers (3) to the evaporator case assembly. 2. Align and install the mode
cam (2) to the mode cam levers (3). Rotate the mode cam (2) to verify mode door operation. 3.
Install the mode cam bracket (1) to the evaporator case assembly.
Notice: Refer to Fastener Notice.
4. Install the mode cam bracket screws to the evaporator case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
5. Install the mode actuator to the evaporator case assembly. 6. Install the mode actuator screws to
the evaporator case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13495
7. Connect the electrical connector to the mode actuator. 8. Install the communication interface
module, if equipped. 9. Install the left side insulator/closeout panel.
Important: Any time a mode actuator or the HVAC control module is replaced, the HVAC control
module must be calibrated to ensure proper air distribution.
10. Calibrate the actuators. Refer to Actuator Recalibration. See: Testing and
Inspection/Programming and Relearning 11. Cycle the ignition and verify proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13496
Air Door Actuator / Motor: Service and Repair Recirculation Actuator Replacement
Recirculation Actuator Replacement
Removal Procedure
1. Remove the instrument panel upper trim panel. 2. Disconnect the electrical connector from the
recirculation actuator. 3. Remove the recirculation actuator screws from the HVAC module. 4.
Remove the recirculation actuator from the HVAC module.
Installation Procedure
1. Align the recirculation actuator with the door shaft and rotate into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Air Temperature Actuator Replacement > Page 13497
Notice: Refer to Fastener Notice.
2. Install the recirculation actuator screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the recirculation actuator. 4. Calibrate the actuators. Refer to
Actuator Recalibration. See: Testing and Inspection/Programming and Relearning 5. Cycle the
ignition and verify proper operation. 6. Install the instrument panel upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side
Air Duct: Service and Repair Instrument Panel Outer Air Outlet Upper Duct Replacement - Left
Side
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side
Removal Procedure
1. Remove the LH I/P trim panel. 2. Remove the LH air outlet duct screws from the instrument
panel retainer.
3. Remove the LH air outlet duct from the instrument panel retainer.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13502
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent. 2. Install the LH air outlet duct to the instrument panel retainer.
Notice: Refer to Fastener Notice.
3. Install the LH air outlet duct screws to the instrument panel retainer.
Tighten the screws to 1 N.m (9 lb in).
4. Install the LH I/P trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13503
Air Duct: Service and Repair Instrument Panel Outer Air Outlet Upper Duct Replacement - Right
Side
Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side
Removal Procedure
1. Remove the RH I/P trim panel. 2. Remove the RH air outlet duct screws from the instrument
panel retainer.
3. Remove the RH air outlet duct from the instrument panel retainer.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13504
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent. 2. Install the RH air outlet duct to the instrument panel retainer.
Notice: Refer to Fastener Notice.
3. Install the RH air outlet duct screws to the instrument panel retainer.
Tighten the screws to 1 N.m (9 lb in).
4. Install the RH I/P trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13505
Air Duct: Service and Repair Center Air Outlet Duct Replacement
Center Air Outlet Duct Replacement
Removal Procedure
1. Remove the instrument panel retainer.
2. Remove the center air outlet duct push pins from the cross car beam. 3. Remove the center air
outlet duct from the cross car beam.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13506
2. Install the center air outlet duct to the cross car beam. 3. Install the center air outlet duct push
pins to the cross car beam. 4. Install the instrument panel retainer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13507
Air Duct: Service and Repair Windshield Defroster Duct Replacement
Windshield Defroster Duct Replacement
Removal Procedure
1. Remove the instrument panel upper trim panel. 2. Remove the windshield defrost duct from the
HVAC module.
Installation Procedure
1. Inspect the windshield defrost duct seals. If damaged, replace using Kent Industries adhesive
back foam tape P/N 46485 or equivalent. 2. Install the windshield defrost duct to the HVAC module.
3. Install the instrument panel upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13508
Air Duct: Service and Repair
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side
Removal Procedure
1. Remove the LH I/P trim panel. 2. Remove the LH air outlet duct screws from the instrument
panel retainer.
3. Remove the LH air outlet duct from the instrument panel retainer.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13509
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent. 2. Install the LH air outlet duct to the instrument panel retainer.
Notice: Refer to Fastener Notice.
3. Install the LH air outlet duct screws to the instrument panel retainer.
Tighten the screws to 1 N.m (9 lb in).
4. Install the LH I/P trim panel.
Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side
Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13510
1. Remove the RH I/P trim panel. 2. Remove the RH air outlet duct screws from the instrument
panel retainer.
3. Remove the RH air outlet duct from the instrument panel retainer.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent. 2. Install the RH air outlet duct to the instrument panel retainer.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13511
Notice: Refer to Fastener Notice.
3. Install the RH air outlet duct screws to the instrument panel retainer.
Tighten the screws to 1 N.m (9 lb in).
4. Install the RH I/P trim panel.
Center Air Outlet Duct Replacement
Center Air Outlet Duct Replacement
Removal Procedure
1. Remove the instrument panel retainer.
2. Remove the center air outlet duct push pins from the cross car beam. 3. Remove the center air
outlet duct from the cross car beam.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13512
2. Install the center air outlet duct to the cross car beam. 3. Install the center air outlet duct push
pins to the cross car beam. 4. Install the instrument panel retainer.
Windshield Defroster Duct Replacement
Windshield Defroster Duct Replacement
Removal Procedure
1. Remove the instrument panel upper trim panel. 2. Remove the windshield defrost duct from the
HVAC module.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13513
1. Inspect the windshield defrost duct seals. If damaged, replace using Kent Industries adhesive
back foam tape P/N 46485 or equivalent. 2. Install the windshield defrost duct to the HVAC module.
3. Install the instrument panel upper trim panel.
Air Inlet Assembly Replacement
Air Inlet Assembly Replacement
Removal Procedure
1. Remove the HVAC module. 2. Disconnect the electrical connector from the recirculation
actuator. 3. Remove the recirculation actuator screws. 4. Remove the recirculation actuator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13514
5. Remove the air inlet assembly screws. 6. Remove the air inlet assembly.
Installation Procedure
1. Install the air inlet assembly.
Notice: Refer to Fastener Notice.
2. Install the air inlet assembly screws.
Tighten the screws to 1.5 N.m (13 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13515
3. Install the recirculation actuator. 4. Install the recirculation actuator screws.
Tighten the screws to 1.5 N.m (13 lb in).
5. Install the electrical connector to the recirculation actuator. 6. Install the HVAC module.
Side Window Defogger Outlet Duct Replacement - Left Side
Side Window Defogger Outlet Duct Replacement - Left Side
Removal Procedure
1. Remove the instrument panel (I/P) upper trim panel.
2. Remove the LH defogger duct screws from the I/P upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13516
3. Remove the LH defogger duct from the I/P upper trim panel.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
2. Install the LH defogger duct to the I/P upper trim panel.
Notice: Refer to Fastener Notice.
3. Install the LH defogger duct screws to the I/P upper trim panel.
Tighten the screws to 1 N.m (9 lb in).
4. Install the instrument panel upper trim panel.
Side Window Defogger Outlet Duct Replacement - Right Side
Side Window Defogger Outlet Duct Replacement - Right Side
Removal Procedure
1. Remove the instrument panel (I/P) upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side > Page 13517
2. Remove the RH defogger duct screws from the I/P upper trim panel. 3. Remove the RH
defogger duct from the I/P upper trim panel.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
2. Install the RH defogger duct to the I/P upper trim panel.
Notice: Refer to Fastener Notice.
3. Install the RH defogger duct screws to the I/P upper trim panel.
Tighten the screws to 1 N.m (9 lb in).
4. Install the instrument panel upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement
Air Register: Service and Repair Defroster Air Outlet Replacement
Defroster Air Outlet Replacement
Removal Procedure
1. Remove the instrument panel (I/P) upper trim panel.
2. Remove the defroster air outlet screws from the I/P upper trim panel. 3. Remove the defroster air
outlet from the I/P upper trim panel.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13522
2. Install the defroster air outlet to the I/P upper trim panel.
Notice: Refer to Fastener Notice.
3. Install the defroster air outlet screws to the I/P upper trim panel.
Tighten the screws to 1 N.m (9 lb in).
4. Install the instrument panel upper trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13523
Air Register: Service and Repair Floor Air Outlet Replacement - Center
Floor Air Outlet Replacement - Center
Removal Procedure
1. Remove the shift control. 2. Slide the center floor air outlet duct forward enough to clear the rear
floor air outlet duct, and then up, and rearward to remove.
Installation Procedure
1. Slide the center floor air outlet duct forward enough to clear rear floor air duct, and then down,
and rearward to install. 2. Install the shift control.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13524
Air Register: Service and Repair Rear Floor Air Outlet Replacement
Rear Floor Air Outlet Replacement
Removal Procedure
1. Remove the front seats. 2. Remove the floor console. 3. Partially remove the floor carpet from
the front footwells to the B-pillars. 4. Remove the rear floor air outlet push pins from the floor pan.
5. Remove the rear floor air outlet from the floor pan.
Installation Procedure
1. Install the rear floor air outlet to the floor pan. 2. Install the rear floor air outlet push pins to the
floor pan. 3. Install the floor carpet to the B-pillars and the front footwells. 4. Install the floor
console. 5. Install the front seats.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13525
Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side
Instrument Panel Outer Air Outlet Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13526
Air Register: Service and Repair
Defroster Air Outlet Replacement
Defroster Air Outlet Replacement
Removal Procedure
1. Remove the instrument panel (I/P) upper trim panel.
2. Remove the defroster air outlet screws from the I/P upper trim panel. 3. Remove the defroster air
outlet from the I/P upper trim panel.
Installation Procedure
1. Inspect the seals, and replace if damaged, using Kent Industries adhesive backed foam tape
P/N 46485 or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13527
2. Install the defroster air outlet to the I/P upper trim panel.
Notice: Refer to Fastener Notice.
3. Install the defroster air outlet screws to the I/P upper trim panel.
Tighten the screws to 1 N.m (9 lb in).
4. Install the instrument panel upper trim panel.
Floor Air Outlet Replacement - Center
Floor Air Outlet Replacement - Center
Removal Procedure
1. Remove the shift control. 2. Slide the center floor air outlet duct forward enough to clear the rear
floor air outlet duct, and then up, and rearward to remove.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13528
1. Slide the center floor air outlet duct forward enough to clear rear floor air duct, and then down,
and rearward to install. 2. Install the shift control.
Rear Floor Air Outlet Replacement
Rear Floor Air Outlet Replacement
Removal Procedure
1. Remove the front seats. 2. Remove the floor console. 3. Partially remove the floor carpet from
the front footwells to the B-pillars. 4. Remove the rear floor air outlet push pins from the floor pan.
5. Remove the rear floor air outlet from the floor pan.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13529
1. Install the rear floor air outlet to the floor pan. 2. Install the rear floor air outlet push pins to the
floor pan. 3. Install the floor carpet to the B-pillars and the front footwells. 4. Install the floor
console. 5. Install the front seats.
Instrument Panel Outer Air Outlet Replacement - Left Side
Instrument Panel Outer Air Outlet Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13530
Instrument Panel Center Air Outlet Replacement
Instrument Panel Center Air Outlet Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13531
Instrument Panel Outer Air Outlet Replacement - Right Side
Instrument Panel Outer Air Outlet Replacement - Right Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
> Defroster Air Outlet Replacement > Page 13532
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front of Vehicle/Engine Compartment Component Views
Behind the Front Fascia Components
1 - Headlamp - Right 2 - Radiator 3 - Ambient Air Temperature Sensor (DH3/DF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 13536
Ambient Temperature Sensor / Switch HVAC: Diagrams
Component Connector End Views
Ambient Air Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 13537
Ambient Temperature Sensor / Switch HVAC: Service and Repair
Ambient Air Temperature Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations
Blower Motor: Locations
Instrument Panel/Center Console Component Views
Front HVAC Module Components
1 - Recirculation Actuator 2 - HVAC Blower Motor 3 - Blower Motor Control Processor 4 - Air
Temperature Actuator 5 - Mode Actuator 6 - Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page
13541
Blower Motor: Diagrams
Component Connector End Views
HVAC Blower Motor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page
13542
Blower Motor: Service and Repair
Blower Motor Replacement
Removal Procedure
1. Remove the right sound insulator panel. 2. Disconnect the electrical connector from the blower
motor. 3. Remove the blower motor screws from the HVAC module. 4. Remove the blower motor
from the HVAC module.
Installation Procedure
1. Install the blower motor to the HVAC module.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page
13543
2. Install the blower motor screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the blower motor. 4. Install the right sound insulator panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement
Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Housing Replacement
Passenger Compartment Air Filter Housing Replacement
Removal Procedure
1. Remove the push pins from the rear of the RH air inlet panel.
2. Open the hood. 3. Remove the push pins from the top and forward edge of the RH air inlet
panel. 4. Remove the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13548
5. Remove the RH air inlet panel. 6. Remove the LH air inlet panel.
7. Remove the filter housing nuts from the vehicle. 8. Remove the filter housing from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13549
1. Inspect the foam seal. If the seal is damaged, replace the seal using Kent Industries adhesive
back foam tape P/N 46485 (or equivalent). 2. Install the filter housing to the vehicle.
Notice: Refer to Fastener Notice.
Important: New seal nuts must be used when installing passenger compartment air filter housing to
prevent leaks.
3. Install the new seal nuts to the filter housing.
Tighten the nuts to 9 N.m (80 lb in).
4. Install the LH air inlet panel. 5. Install the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13550
6. Install the push pins and screw to the top and forward edge of the RH air inlet panel. 7. Close the
hood.
8. Install the push pins to the rear of the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13551
Cabin Air Filter: Service and Repair Passenger Compartment Air Filter Replacement
Passenger Compartment Air Filter Replacement
Removal Procedure
1. Remove the push pins from the rear of the RH air inlet panel.
2. Open the hood. 3. Remove the push pins from the top and forward edge of the RH air inlet
panel. 4. Remove the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13552
5. Remove the RH air inlet panel.
6. Remove the filter from the filter housing by depressing the release tab at the inboard edge of the
filter housing. 7. Remove the filter from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13553
1. Install the filter to the vehicle.
2. Install the RH air inlet panel. 3. Install the RH air inlet panel screw.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and
Repair > Passenger Compartment Air Filter Housing Replacement > Page 13554
4. Install the push pins to the top and forward edge of the RH air inlet panel. 5. Close the hood.
6. Install the push pins to the rear of the RH air inlet panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Clutch Gap............................................................................................................................................
...................................0.3 - 0.6 mm (0.012 - 0.024 in)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13559
Compressor Clutch: Diagrams
Component Connector End Views
A/C Compressor Clutch (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13560
Compressor Clutch: Service and Repair
Compressor Clutch Assembly Replacement
Tools Required
* J 25031-A Three Jaw Puller
* J 37872 Universal Spanner Wrench
* GE-47849 Clutch Remover
* GE-47850 Center Puller
* GE-47851 Armature Replacer
Removal Procedure
1. Remove the compressor from the vehicle.
2. Use J 37872 to hold the compressor clutch.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13561
3. Remove the bolt retaining the compressor clutch to the compressor.
4. Install GE-47849 to the compressor clutch. 5. Using GE-47849, remove the compressor clutch
from the compressor. 6. Remove the compressor clutch shims from the compressor shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13562
7. Remove the snap ring from the compressor pulley. 8. Using GE-47850 with J 25031-A, remove
the compressor pulley from the compressor.
9. Remove the clutch field coil connector bracket screw from the compressor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13563
10. Remove the clutch field coil screws from the compressor.
11. Remove the clutch field coil from the compressor.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13564
1. Clean the clutch field coil and the pulley mounting surfaces. 2. Install the clutch field coil to the
compressor.
Notice: Refer to Fastener Notice.
3. Install the clutch field coil screws to the compressor.
Tighten the screws to 4.9 N.m (43 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13565
4. Install the clutch field coil connector bracket screw to the compressor.
Tighten the screws to 4.3 N.m (38 lb in).
5. Using GE-47851, install the compressor pulley to the compressor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13566
Important: Ensure that the compressor pulley snap ring is installed with the rounded edge face up.
6. Install the snap ring to the compressor pulley. 7. Install the compressor clutch shims to the
compressor shaft. 8. Align the compressor clutch with the compressor shaft and install to the
compressor.
9. Using GE-47851, install the compressor clutch to the compressor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 13567
10. Using a feeler gage, check the clearance between the compressor clutch and the compressor
pulley. Ensure the clearance is 0.3 mm to 0.6 mm
(0.012 in to 0.024 in).
11. Once the correct air gap is obtained, install the new clutch bolt. 12. Using J 37872 to hold the
compressor clutch, tighten the clutch bolt.
Tighten the bolt to 21 N.m (16 lb ft).
13. After the clutch bolt is installed, verify that the compressor pulley spins freely. 14. Install the
compressor to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Recalls for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser Shield Removal
Technical Service Bulletin # 08278 Date: 080905
Campaign - A/C Condenser Shield Removal
# 08278: Customer Satisfaction - Loss of Air Conditioning - Remove Condenser Shield - (Sep 5,
2008)
Subject: 08278 -- Loss of Air Conditioning - Remove Condenser Shield
Models: 2008 Chevrolet Equinox
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2009.
Condition
Certain 2008 model year Chevrolet Equinox vehicles may have a condition in which the center
retaining features of the air conditioning condenser shield can rub against the air conditioning
condenser tubes. This could cause a leak and loss of air conditioning function.
Correction
Dealers are to remove the air conditioning condenser shield.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox vehicles built within the VIN breakpoints
shown above.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
- US dealers - GM DealerWorld Recall Information
- Canadian dealers - GMinfoNet Recall Reports
- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
No parts are required for this program.
Service Procedure
1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Locate the HVAC condenser and stone shield. The HVAC condenser and stone shield can be
accessed through an opening located on the bottom side of the front bumper and fascia.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Recalls for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser Shield Removal >
Page 13579
3. There are six tabs (1) securing the shield to the HVAC condenser. Refer to the illustration.
Notice:
To avoid damaging the HVAC condenser, do NOT use a screw driver, pry bar, or equivalent to
remove the shield.
4. Remove the center two shield tabs (2) first by inserting your hands between the HVAC
condenser and the shield. Gently pry the shield away from the HVAC condenser until the top and
bottom center tabs release from the condenser.
5. Remove the two tabs (3) located on the passenger's side of the shield.
6. Remove the two tabs (3) located on the driver's side of the shield.
7. Lower the vehicle.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Recalls for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser Shield Removal >
Page 13580
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer Program Responsibility -- All
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of
mileage, age of vehicle, or ownership, through September 30, 2009.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Program follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership for service through September 30, 2009, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Recalls for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser Shield Removal >
Page 13581
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser
Shield Removal
Technical Service Bulletin # 08278 Date: 080905
Campaign - A/C Condenser Shield Removal
# 08278: Customer Satisfaction - Loss of Air Conditioning - Remove Condenser Shield - (Sep 5,
2008)
Subject: 08278 -- Loss of Air Conditioning - Remove Condenser Shield
Models: 2008 Chevrolet Equinox
THIS PROGRAM IS IN EFFECT UNTIL SEPTEMBER 30, 2009.
Condition
Certain 2008 model year Chevrolet Equinox vehicles may have a condition in which the center
retaining features of the air conditioning condenser shield can rub against the air conditioning
condenser tubes. This could cause a leak and loss of air conditioning function.
Correction
Dealers are to remove the air conditioning condenser shield.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox vehicles built within the VIN breakpoints
shown above.
Important:
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
- US dealers - GM DealerWorld Recall Information
- Canadian dealers - GMinfoNet Recall Reports
- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
No parts are required for this program.
Service Procedure
1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Locate the HVAC condenser and stone shield. The HVAC condenser and stone shield can be
accessed through an opening located on the bottom side of the front bumper and fascia.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser
Shield Removal > Page 13587
3. There are six tabs (1) securing the shield to the HVAC condenser. Refer to the illustration.
Notice:
To avoid damaging the HVAC condenser, do NOT use a screw driver, pry bar, or equivalent to
remove the shield.
4. Remove the center two shield tabs (2) first by inserting your hands between the HVAC
condenser and the shield. Gently pry the shield away from the HVAC condenser until the top and
bottom center tabs release from the condenser.
5. Remove the two tabs (3) located on the passenger's side of the shield.
6. Remove the two tabs (3) located on the driver's side of the shield.
7. Lower the vehicle.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this program on their vehicle (see copy of customer letter
shown in this bulletin).
Customer Notification - For Export
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser
Shield Removal > Page 13588
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
Dealer Program Responsibility -- All
All unsold new vehicles in dealers' possession and subject to this program must be held and
inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of
mileage, age of vehicle, or ownership, through September 30, 2009.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Program follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership for service through September 30, 2009, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 08278 > Sep > 08 > Campaign - A/C Condenser
Shield Removal > Page 13589
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13590
Condenser HVAC: Service and Repair
Condenser Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the front
fascia. 3. For Pontiac models, remove the hood latch.
4. Remove the battery box air duct.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13591
5. Remove the condenser radiator fan module (CRFM) closeout panel.
6. Remove the liquid line nut from the condenser. 7. Remove the liquid line from the condenser. 8.
Install a protective cap to the liquid line to prevent contamination and desiccant saturation.
9. Remove the compressor hose nut from the condenser.
10. Remove the compressor hose from the condenser. 11. Install a protective cap to the
compressor hose to prevent contamination and desiccant saturation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13592
12. Remove the CRFM bracket bolts from the radiator support. 13. Remove the CRFM brackets
from the vehicle.
14. Remove the bolts retaining the top of the condenser to the radiator. 15. Remove the condenser
from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13593
1. Add the specified amount of PAG oil to the condenser. Refer to Refrigerant System Capacities.
2. Inspect the radiator to condenser seals for the proper position. 3. Install the condenser to the
lower retention clips on the radiator.
Notice: Refer to Fastener Notice.
4. Install the bolts to retain the top of the condenser to the radiator.
Tighten the bolts to 9 N.m (80 lb in).
5. Install the CRFM brackets to the vehicle. 6. Install the CRFM bracket bolts to the radiator
support.
Tighten the bolts to 20 N.m (15 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13594
7. Remove the protective cap from the compressor hose. 8. Install a new sealing washer to the
compressor hose. 9. Install the compressor hose to the condenser.
10. Install compressor hose nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
11. Install a new seal washer to the liquid line. 12. Install the liquid line to the condenser. 13. Install
the liquid line nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical
Service Bulletins > Page 13595
14. Install the CRFM closeout panel.
15. Install the battery box air duct. 16. For Pontiac models, install the hood latch assembly. 17.
Install the front fascia. 18. Evacuate and charge the A/C system. Refer to Refrigerant Recovery
and Recharging. 19. Test the affected A/C joints leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > A/C - Indicators Flashing (Normal Condition)
Control Assembly: Technical Service Bulletins A/C - Indicators Flashing (Normal Condition)
Bulletin No.: 07-01-38-003
Date: June 12, 2007
INFORMATION
Subject: Information for Vehicles with HVAC Control Module A/C And Recirculation Indicators
Flashing
Models: 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2006-2007 Chevrolet Monte
Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Avalanche, Equinox, Silverado, Suburban,
Tahoe 2007-2008 GMC Acadia, Sierra, Yukon Models 2007-2008 Pontiac Torrent 2008 HUMMER
H2 2007-2008 Saturn OUTLOOK 2008 Saturn VUE
Condition/Concern
Some customers may comment that the Air Conditioning (A/C) indicator on the Heating Ventilation
and Air Conditioning (HVAC) Control Module flashes then turns off after they press the A/C button.
Others may comment that the Recirculation indicator on the HVAC Control Module flashes then
turns off after they press the Recirculation button.
This is normal operation for the HVAC Control Module and indicates that the A/C or Recirculation
function is not available at this time.
Reasons that the A/C may not be available (calibrated values vary by program) are listed below.
Consult the appropriate vehicle Service Information (SI) for detailed HVAC Description and
Operation:
Ambient Air Temperature is too low (if equipped with Ambient Air Temperature Sensor)
Vehicle voltage less than 9.5 volts
Refrigerant Pressure too low
Refrigerant Pressure too high
Engine Coolant Temperature too high
Engine is not in RUN
HVAC Control Head is in the OFF position
Reasons Recirculation may not be available: Mode switch in Floor, Defog or Defrost mode.
The reason(s) A/C is currently disabled can be viewed with a Tech 2(R) by navigating to HVAC
Data display and viewing the "A/C Permission" parameter.
Recommendation/Instructions
Do not replace the HVAC Control Module for a flashing A/C Indicator or flashing Recirculation
Indicator, as this is normal operation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 13600
Control Assembly: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 13601
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 13602
Control Assembly: Diagrams
Component Connector End Views
HVAC Control Module - X1
HVAC Control Module - X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 13603
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 13604
Control Assembly: Service and Repair
HVAC Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information >
Diagrams
Control Module HVAC: Diagrams
Component Connector End Views
Blower Motor Control Processor - X1
Blower Motor Control Processor - X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information >
Diagrams > Page 13608
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information >
Diagrams > Page 13609
Control Module HVAC: Service and Repair
Blower Motor Control Module Replacement
Removal Procedure
1. Remove Right Lower Insulator Panel 2. Disconnect the electrical connector from the blower
motor control module. 3. Remove the blower control module screws from the HVAC module. 4.
Remove the blower motor control module from the HVAC module.
Installation Procedure
1. Install the blower motor control module to the HVAC module.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information >
Diagrams > Page 13610
2. Install the blower motor control module screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the blower motor control module. 4. Install Right Lower
Insulator Panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement
A/C Coupler O-ring: Service and Repair Sealing Washer Replacement
Sealing Washer Replacement
Removal Procedure
1. Remove the seal washer from the A/C refrigerant component.
Important: Cap or tape the open A/C refrigerant components immediately to prevent system
contamination.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3.
Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
Important: DO NOT reuse sealing washer.
4. Discard the sealing washer.
Installation Procedure
Important: Flat washer type seals do not require lubrication.
1. Inspect the new seal washer for any signs of cracks, cuts, or damage.
Do not use a damaged seal washer.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4.
Carefully install the new seal washer onto the A/C refrigerant component.
The washer must completely bottom against the surface of the fitting.
Important: After tightening the A/C components, there should be a slight sealing washer gap of
approximately 1.2 mm (3/64 in) between the A/C line and the A/C component.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement > Page 13616
A/C Coupler O-ring: Service and Repair O-Ring Replacement
O-Ring Replacement
Removal Procedure
1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure
* For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1).
* For banjo style fittings remove the bolt retaining the banjo type fitting.
2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs
of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant
components for damage or burrs. Repair if necessary.
Important: Cap or tape the open A/C refrigerant components immediately to prevent system
contamination.
5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal.
Installation Procedure
1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2.
Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth,
carefully clean the sealing surfaces of the A/C refrigerant components.
Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring
seal to enter the refrigerant system.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
Important: DO NOT reuse O-ring seals.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component
Information > Service and Repair > Sealing Washer Replacement > Page 13617
7. Assemble the A/C components.
Refer to the appropriate repair procedure.
* For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1)
to specification.
* For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair
Evaporator Case: Service and Repair
Air Conditioning (A/C) Evaporator Case Assembly Replacement
Removal Procedure
1. Remove the HVAC module.
2. Remove the heater core cover screws from the evaporator case assembly. 3. Remove the
heater core cover from the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Page 13621
4. Remove the heater core from the HVAC module.
5. Remove the evaporator case assembly screws from the blower case assembly. 6. Remove the
evaporator case assembly from the blower case assembly.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Page 13622
1. Install evaporator case assembly to the blower case assembly.
Notice: Refer to Fastener Notice.
2. Install evaporator case assembly screws to the blower case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
3. Install heater core to the HVAC module.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Page 13623
4. Install heater core cover. 5. Install heater core cover screws.
Tighten the screws to 1.5 N.m (13 lb in).
6. Install the HVAC module.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System
Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System
TECHNICAL
Bulletin No.: 99-01-39-004C
Date: June 12, 2009
Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)
Models:
1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All
Equipped with Air Conditioning
Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard
Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC).
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air
Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.
Cause
This condition may be caused by condensate build-up on the evaporator core, which does not
evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on
the evaporator core. When the blower motor fan is turned on, the microbial growth may release an
unpleasant musty odor into the passenger compartment.
There are several other possible sources of a musty odor in a vehicle. A common source is a water
leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow
the procedures in SI for identifying and correcting water leaks and air inlet inspection.
The procedure contained in this bulletin is only applicable if the odor source has been determined
to be microbial growth on the evaporator core inside the HVAC module.
Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module
software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the
evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to
confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded
afterblow feature, as defined in the SI document for that specific vehicle model, model year and
specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in
areas prone to high humidity conditions may benefit from having the afterblow enabled calibration
installed prior to any customer comment.
Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may
be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).
Important When installing the Electronic Evaporator Dryer Module, you MUST use the included
electrical splice connectors to ensure a proper splice. Complete detailed installation instructions
and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer
Module may be installed underhood if it is protected from extreme heat and water splash areas.
To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to
eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the
following procedure:
Vehicle and Applicator Tool Preparation
1. The evaporator core must be dry. This may be accomplished by disabling the compressor and
running the blower fan on the recirc heat setting for
an extended period of time.
Note Compressor engagement will cause the evaporator core to remain wet and will prevent full
adherence of the Coiling Coil Coating to the evaporator core surfaces.
2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 13632
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From
(HVAC) System > Page 13633
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System
Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System
TECHNICAL
Bulletin No.: 99-01-39-004C
Date: June 12, 2009
Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating)
Models:
1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All
Equipped with Air Conditioning
Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard
Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC).
Condition
Some customers may comment about musty odors emitted from the Heating, Ventilation and Air
Conditioning (HVAC) system at vehicle start-up in hot, humid conditions.
Cause
This condition may be caused by condensate build-up on the evaporator core, which does not
evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on
the evaporator core. When the blower motor fan is turned on, the microbial growth may release an
unpleasant musty odor into the passenger compartment.
There are several other possible sources of a musty odor in a vehicle. A common source is a water
leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow
the procedures in SI for identifying and correcting water leaks and air inlet inspection.
The procedure contained in this bulletin is only applicable if the odor source has been determined
to be microbial growth on the evaporator core inside the HVAC module.
Correction
Many vehicles currently incorporate an afterblow function within the HVAC control module
software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the
evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to
confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded
afterblow feature, as defined in the SI document for that specific vehicle model, model year and
specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in
areas prone to high humidity conditions may benefit from having the afterblow enabled calibration
installed prior to any customer comment.
Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may
be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876).
Important When installing the Electronic Evaporator Dryer Module, you MUST use the included
electrical splice connectors to ensure a proper splice. Complete detailed installation instructions
and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer
Module may be installed underhood if it is protected from extreme heat and water splash areas.
To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to
eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the
following procedure:
Vehicle and Applicator Tool Preparation
1. The evaporator core must be dry. This may be accomplished by disabling the compressor and
running the blower fan on the recirc heat setting for
an extended period of time.
Note Compressor engagement will cause the evaporator core to remain wet and will prevent full
adherence of the Coiling Coil Coating to the evaporator core surfaces.
2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the
vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System > Page 13639
3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air
filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product
may clog the filter. If the
cabin air filter appears to have little or no remaining life, suggest a replacement to your customer.
5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE
COOLING COIL COATING INTO THE
BLOWER MOTOR COOLING TUBE.
6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line
operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well.
Screw the bottle onto the cap on the applicator tool's pick-up tube.
Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil
slightly in the bottom of a 120 ml (4 oz) bottle.
8. Use one of the following three methods to apply the Cooling Coil Coating.
Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil
Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)).
Application Through Blower Motor Control Module Opening
- Remove the blower motor control module (blower motor resistor). Refer to the applicable
procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower
motor control module (blower motor resistor) opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor blower motor control module (blower
motor control module).
Application Through Blower Motor Opening
- Remove the blower motor. Refer to the applicable blower motor removal procedure in SI.
- Clean any debris or foreign material from inside the HVAC module and on the evaporator core
surface.
- Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening.
- Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and
surrounding gasket surfaces.
- When the application is complete, install the blower motor.
Application Through a Hole in the HVAC Module
- If neither of the two previous application methods are available, it may be necessary to drill a hole
in the HVAC module.
- Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10
mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and
the blower motor fan.
- With the air distribution vents closed and the blower motor fan speed on HIGH, insert the
applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the
evaporator core.
- Use a GM approved RTV sealant to plug the hole in the HVAC module.
9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately
10 minutes, with the compressor disabled,
HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and
one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the
evaporator core surface.
10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the
tool. Be sure to spray warm water through the
nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it
will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and
rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged ,
the Cooling Coil Coating will not flow through the applicator tool.
11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system
operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from
underneath the vehicle. 15. Reinstall the cabin air filter if necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors
Emitted From (HVAC) System > Page 13640
Parts Information
Important The Cooling Coil Coating listed below is the only GM approved product for use under
warranty as an evaporator core disinfectant and for the long term control of evaporator core
microbial growth.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 13641
Evaporator Core: Service and Repair
Air Conditioning Evaporator Core Replacement
1. Remove the HVAC module. 2. Remove the evaporator case assembly. 3. Remove the thermal
expansion valve (TXV) bolts from the backing plate. 4. Remove the TXV and the backing plate from
the evaporator pipes. 5. Remove the seal washers from evaporator pipes. 6. Remove the HVAC
module front of dash seal.
7. Remove the screws retaining the two halves of the blower case assembly. 8. Separate the two
halves of the blower case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 13642
9. Remove the evaporator core from the blower case assembly.
Installation Procedure
1. Add the proper of polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant
System Capacities. 2. Inspect the seal around the evaporator core. Make sure the seal is in correct
position and retained properly. 3. Install the evaporator core to the blower case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 13643
4. Assemble the two halves of the blower case assembly.
Notice: Refer to Fastener Notice.
5. Install the blower case assembly screws.
Tighten the screw to 1.5 N.m (13 lb in).
6. Install the HVAC module front of dash seal.
7. Install new seal washers to the evaporator pipes. 8. Instal the TXV and the backing plate to the
evaporator pipes. 9. Install the TXV screws to the backing plate.
Tighten the screws to 3.5 N.m (31 lb in).
10. Install the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical
Service Bulletins > Page 13644
11. Install the HVAC module.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations
Evaporator Temperature Sensor / Switch: Locations
Instrument Panel/Center Console Component Views
Front HVAC Module Components
1 - Recirculation Actuator 2 - HVAC Blower Motor 3 - Blower Motor Control Processor 4 - Air
Temperature Actuator 5 - Mode Actuator 6 - Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations > Page 13648
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair
Expansion Valve: Service and Repair
Thermal Expansion Valve Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
Important: When removing the thermal expansion valve (TXV), keep dirt and foreign material from
getting on or into the sealing surfaces. Clean tools and a clean work area are important for proper
service. The TXV seal area should be cleaned before any repairs are performed. The parts must
be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum
based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to
enter evaporator or hoses.
2. Remove the evaporator outlet hose and liquid line retainer plate nut from the TXV. 3. Remove
the evaporator outlet hose and liquid line from the TXV. 4. Remove and discard the sealing
washers from the evaporator outlet hose and liquid line. 5. Install protective caps to the evaporator
outlet hose and the liquid line to prevent contamination and desiccant saturation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Page 13652
6. Remove the TXV bolts from the backing plate. 7. Remove the TXV and the backing plate from
the vehicle. 8. Remove and discard the seal washers from the evaporator pipes. 9. Install a
protective cap to the evaporator pipes to prevent contamination and desiccant saturation.
Installation Procedure
Important: Use only lint free cloths to wipe parts. Do not allow any solvent to enter evaporator or
hoses.
1. Remove the protective caps from the evaporator pipes and ensure the seal areas are clean, dry
and lint free. 2. Install new seal washers to the evaporator pipes. 3. Remove the protective caps
from the TXV. 4. Install the TXV and the backing plate to the evaporator pipes.
Notice: Refer to Fastener Notice.
5. Install the TXV bolts to the backing plate.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Page 13653
Tighten the bolts to 3.5 N.m (31 lb in).
6. Remove the protective caps from the liquid line and the evaporator outlet hose. 7. Install new
seal washers to the liquid line and the evaporator outlet hose. 8. Install the liquid line and the
evaporator outlet hose to the TXV. 9. Install the liquid line and evaporator outlet hose retainer plate
nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
10. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Test
the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators
Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators
INFORMATION
Bulletin No.: 05-06-02-001A
Date: July 16, 2008
Subject: Information On Aluminum Heater Core and/or Radiator Replacement
Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005
HUMMER H2
Supercede:
This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin
Number 05-06-02-001 (Section 06 - Engine/Propulsion System).
Important:
2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the
flushing procedure explained later in this bulletin.
The following information should be utilized when servicing aluminum heater core and/or radiators
on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient
inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check
should be performed whenever a heater core, radiator, or water pump is replaced. The following
procedures/ inspections should be done to verify proper coolant effectiveness.
Caution:
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot.
The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge
tank cap is removed while the engine and radiator are still hot.
Important:
If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water
to the system, then the system should be completely flushed using the procedure explained later in
this bulletin.
Technician Diagnosis
^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion
protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the
measurement of coolant concentration. This must be done by using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer
uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or
the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the
coolant concentration fully and should not be used. The concentration levels should be between
50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees
Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be
flushed.
^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information
(SI) and/or the appropriate Service Manual for component location and condition for operation.
^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed
before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test
lead to the negative battery post and insert the other test lead into the radiator coolant, making sure
the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that
stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that
occurs when a device or accessory that is mounted to the radiator is energized. This type of current
could be caused from a poorly grounded cooling fan or some other accessory and can be verified
by watching the volt meter and turning on and off various accessories or engage the starter motor.
Before using one of the following flush procedures, the coolant recovery reservoir must be
removed, drained, cleaned and reinstalled before refilling the system.
Notice:
^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or
radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles
(50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your
warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle.
^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The
repair cost would not be covered by your warranty. Too much water in the mixture can freeze and
crack the engine, radiator, heater core and other parts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 13658
Flushing Procedures using DEX-COOL(R)
Important:
The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in
Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a
service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior
to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the
Owner's Manual.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of
properly following the draining procedures in the appropriate Service Manual. Refill the system
using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the
vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear.
Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with
DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R),
P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear,
drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached
the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add
clean water to restore the coolant to the appropriate level.
Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration
levels should be between 50% and 65%.
Flushing Procedures using Conventional Silicated (Green Colored) Coolant
Important:
2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R).
The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color.
Silicated coolants are typically green in color and are required to be drained, flushed and refilled
every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated
coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's
Manual or Service Information (SI) for further information on OEM coolant.
Important:
Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when
adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and
green colored coolants will produce a brown coolant which may be a customer dissatisfier and will
not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by
GM Service and Parts Operations are green in color.
^ If available, use the approved cooling system flush and fill machine (available through the GM
Dealer Equipment Program) following the manufacturer's operating instructions.
^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of
properly following the draining procedures in appropriate Service Manual. Refill the system using
clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3)
times to totally remove old coolant or until drained coolant is almost clear. Once the system is
completely flushed, refill the cooling system to a 50%-60% concentration with a good quality
ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L),
conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M,
following the refill procedures in the appropriate Service Manual.
If a Service Manual is not available, fill half the capacity of the system with 100% good quality
ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N
88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water
(preferably distilled) to system until the level of the coolant mixture has reached the base of the
radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to
restore coolant to the appropriate level.
Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688
(Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels
should be between 50% and 65%.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 13659
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 13660
Heater Core: Service and Repair
Heater Core Replacement
Removal Procedure
1. Remove the HVAC module from the vehicle.
2. Remove the heater core cover screws from the HVAC module.
3. Remove the heater core cover from the HVAC module.
4. Remove the heater core from the HVAC module.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 13661
1. Install the heater core to the HVAC module.
2. Install the heater core cover to the HVAC module.
Notice: Refer to Fastener Notice.
3. Install the heater core cover screws to the HVAC module.
Tighten the screw to 1.5 N.m (13 lb in).
4. Install the HVAC module to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ)
Heater Hose: Service and Repair Heater Inlet Hose Replacement (LNJ)
Heater Inlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater inlet hose clamp from the heater core. 3. Remove the heater inlet hose (2)
from the heater core.
4. Remove the heater inlet hose clamp from the engine. 5. Remove the heater inlet hose (2) from
the engine. 6. Remove the heater inlet hose (2) from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ) > Page 13666
Installation Procedure
1. Install the heater inlet hose (2) to the vehicle. 2. Install the heater inlet hose (2) to the engine. 3.
Install the heater inlet hose clamp to the engine.
4. Install the heater inlet hose (2) to the heater core. 5. Install the heater inlet hose clamp to the
heater core. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (LNJ Static Fill)
Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ) > Page 13667
Heater Hose: Service and Repair Heater Outlet Hose Replacement (LNJ)
Heater Outlet Hose Replacement (LNJ)
Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling (LNJ Static Fill) Cooling
System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
2. Remove the heater outlet hose clamp from the heater core. 3. Remove the heater outlet hose (1)
from the heater core.
4. Remove the heater outlet hose clamp from the engine. 5. Remove the heater outlet hose (1)
from the engine. 6. Position the loose end of the heater outlet hose (1) outboard to ease in the
removal of the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ) > Page 13668
7. Remove the surge tank inlet hose clamp from the surge tank. 8. Disconnect the surge tank inlet
hose from the surge tank.
9. Remove the surge tank bolts from the surge tank.
10. Lift the surge tank to gain access to the heater outlet hose. 11. Remove the heater outlet hose
clamp from the surge tank. 12. Remove the heater outlet hose from the surge tank. 13. Remove
the surge tank from the vehicle. 14. Remove the heater outlet hose clamp from the hose. This will
aid in routing the heater outlet hose from the vehicle. 15. Remove the heater outlet hose from the
vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ) > Page 13669
1. Install the heater outlet hose to the vehicle. Route the hose into position for attachment to the
surge tank. 2. Install the heater outlet hose clamp to the hose. 3. Install the heater outlet hose to
the surge tank. 4. Install the surge tank to the vehicle.
Notice: Refer to Fastener Notice.
5. Install the surge tank bolts to the surge tank.
Tighten the bolts to 8 N.m (71 lb in).
6. Connect the surge tank inlet hose to the surge tank. 7. Install the surge tank inlet hose clamp to
the surge tank.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and
Repair > Heater Inlet Hose Replacement (LNJ) > Page 13670
8. Install the heater outlet hose (1) to the engine. 9. Install the heater outlet hose clamp to the
engine.
10. Install the heater outlet hose (1) to the heater core. 11. Install the heater outlet hose clamp to
the heater core. 12. Fill the engine coolant. Refer to Cooling System Draining and Filling (LNJ
Static Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill)
Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE
47716 Fill).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component
Information > Service and Repair
High Pressure Safety Valve HVAC: Service and Repair
Compressor Pressure Relief Valve Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise and support
the vehicle. Refer to Vehicle Lifting.
3. Remove the pressure relief valve from the compressor. 4. Remove and discard the O-ring from
the pressure relief valve.
Installation Procedure
Important: Lubricate the new O-ring prior to installation on the compressor hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component
Information > Service and Repair > Page 13674
1. Lightly coat the new O-ring with mineral base 525 viscosity refrigerant oil. 2. Install the new
O-ring to the pressure relief valve.
Notice: Refer to Fastener Notice.
3. Install the pressure relief valve to the compressor.
Tighten the pressure relief valve to 8.8 N.m (78 lb in).
4. Lower the vehicle. Refer to Vehicle Lifting. 5. Recharge the A/C system. Refer to Refrigerant
Recovery and Recharging. 6. Test the affected A/C joint for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ)
Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement (LNJ)
Compressor Hose Assembly Replacement (LNJ)
Special Tools
J 39400-A Halogen Leak Detector
Removal Procedures
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the left
headlamp.
3. Remove the compressor hose retainer nut from the battery box. 4. Remove the evaporator outlet
hose nut from the evaporator outlet hose. 5. Remove the evaporator outlet hose from the
compressor hose. 6. Install a protective cap to the evaporator outlet hose to prevent contamination
and desiccant saturation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13679
7. Remove the compressor hose nut from the condenser. 8. Remove the compressor hose from
the condenser. 9. Install a protective cap to the condenser to prevent contamination and desiccant
saturation.
10. Raise and support the vehicle. Refer to Vehicle Lifting.
11. Disconnect the electrical connector from the pressure transducer. 12. Remove the compressor
hose nut at the compressor. 13. Remove the compressor hose from the compressor. 14. Install a
protective cap to the compressor to prevent contamination and desiccant saturation. 15. Remove
the compressor hose from the vehicle. 16. Remove and discard the sealing washers from the
compressor hose.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13680
1. Remove protective cap from compressor end of the compressor hose and the compressor. 2.
Install new seal washers to the compressor hose. 3. Install the compressor hose to the
compressor.
Notice: Refer to Fastener Notice.
4. Install the compressor hose nut to the compressor.
Tighten the nut to 20 N.m (15 lb ft).
5. Connect the electrical connector to the pressure transducer.
6. Lower the vehicle. 7. Position the compressor hose in the vehicle. 8. Install a new sealing
washer to the evaporator outlet hose. 9. Install the evaporator outlet hose to the compressor hose.
10. Install the evaporator outlet hose nut to the evaporator outlet hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13681
Tighten the nut to 20 N.m (15 lb ft).
11. Install a new sealing washer to the compressor hose at the condenser. 12. Install the
compressor hose to the condenser. 13. Install the compressor hose nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
14. Install the compressor hose retainer nut to the battery box.
Tighten the nut to 9 N.m (80 lb in).
15. Install the left headlamp. 16. Recharge the A/C system. Refer to Refrigerant Recovery and
Recharging. 17. Test the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13682
Hose/Line HVAC: Service and Repair Evaporator Outlet Hose Replacement
Evaporator Outlet Hose Replacement
Tools Required
J 39400-A Halogen Leak Detector
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the
evaporator outlet hose nut from the evaporator outlet hose. 3. Remove the evaporator outlet hose
from the compressor hose.
4. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion
valve (TXV). 5. Remove the evaporator outlet hose and liquid line from the TXV. 6. Remove
evaporator outlet hose from the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13683
7. Remove and discard the sealing washers from the evaporator outlet hose and the compressor
hose. 8. Install protective caps to the TXV, the liquid line, and the compressor hose to prevent
contamination and desiccant saturation.
Installation Procedure
1. Remove the protective caps from the TXV, the liquid line, and the compressor hose. 2. Install
new sealing washers to the evaporator outlet hose, liquid line, and the compressor hose. 3. Install
the evaporator outlet hose and the liquid line to the TXV.
Notice: Refer to Fastener Notice.
4. Install the evaporator outlet hose and the liquid line nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
5. Install the evaporator outlet hose to the compressor hose. 6. Install the evaporator outlet hose
nut to the evaporator outlet hose.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13684
Tighten the nut to 20 N.m (15 lb ft).
7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Test the affected
A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13685
Hose/Line HVAC: Service and Repair Liquid Line Replacement
Liquid Line Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the left
headlamp. 3. Remove the surge tank. 4. Remove the washer bottle. 5. Remove the battery. 6.
Remove the battery box bolts from the battery box. 7. Disconnect the negative battery cable nut
from the wheelhouse.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13686
8. Remove the nut retaining the liquid line to the strut tower. 9. Disconnect the harness and vent
hose retainers from the liquid line.
10. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion
valve (TXV). 11. Remove the evaporator outlet hose and liquid line from the TXV.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13687
12. Remove the liquid line nut from the condenser. 13. Remove the liquid line from the condenser.
14. Remove the bolt retaining the liquid line to the body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13688
15. Position the battery box inboard to allow for routing of the liquid line. 16. Route the liquid line
above the battery box and the ground lug. 17. Lift the rear portion of the liquid line upward and
remove the liquid line from the vehicle. 18. Remove and discard the sealing washer from the liquid
line. 19. Install protective caps to the condenser, the evaporator outlet hose, and the TXV to
prevent contamination and desiccant saturation.
Installation Procedure
1. Route the liquid line below the battery box and the ground lug.
Notice: Refer to Fastener Notice.
2. Connect the negative battery cable nut to the wheelhouse.
Tighten the nut to 12 N.m (106 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13689
3. Remove the protective caps from the condenser, the evaporator outlet hose, and the TXV. 4.
Install the new sealing washer to the liquid line. 5. Route the condenser end of the liquid line into
position. 6. Install the liquid line to the condenser.
Important: Use a large pair of pliers to hold the fitting while tightening the nut. Be careful not to twist
the line.
7. Install the liquid line nut to the condenser.
Tighten the nut to 20 N.m (15 lb ft).
8. Install the bolt to retain the liquid line to the body.
Tighten the nut to 9 N.m (80 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13690
9. Remove the protective cap from the TXV, the liquid line, and the evaporator outlet hose.
10. Install new seal washers to the liquid line and the evaporator outlet hose. 11. Install the liquid
line and the evaporator outlet hose to the TXV. 12. Install the liquid line and evaporator outlet hose
retainer plate nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
13. Install the four battery box bolts to the inside of the battery box.
Tighten the nut to 15 N.m (11 lb ft).
14. Install the battery box bolt to the outside of the battery box.
Tighten the nut to 10 N.m (86 lb in).
15. Install the battery.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > Compressor Hose Assembly Replacement (LNJ) > Page 13691
16. Install the liquid line to the strut tower. 17. Install the liquid line nut to the strut tower.
Tighten the nut to 9 N.m (80 lb in).
18. Connect the harness and vent hose retainers to the liquid line. 19. Install the surge tank. 20.
Install the washer bottle. 21. Install the left headlamp. 22. Recharge the A/C system. Refer to
Refrigerant Recovery and Recharging. 23. Test the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement
Housing Assembly HVAC: Service and Repair Blower Case Assembly Replacement
Blower Case Assembly Replacement
Removal Procedure
1. Remove the HVAC module assembly. 2. Remove the evaporator case assembly. 3. Remove the
air inlet assembly.
4. Remove the blower motor screws from the blower case assembly. 5. Remove the blower motor
from the blower case assembly.
6. Remove the blower motor control module screws from the blower case assembly. 7. Remove the
blower motor control module from the blower case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13696
8. Remove the screws retaining the two halves of the blower case assembly. 9. Separate the two
halves of the blower case assembly.
10. Remove the evaporator core from the blower case assembly.
Installation Procedure
1. Install the evaporator core to the blower case assembly. 2. Assemble the two halves of the
blower case assembly.
Notice: Refer to Fastener Notice.
3. Install the screws to retain the two halves of the blower case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13697
4. Install the blower motor control module to the blower case assembly. 5. Install the blower motor
control module screws to the blower case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
6. Install the blower motor to the blower case assembly. 7. Install the blower motor screws to the
blower case assembly.
Tighten the screws to 1.5 N.m (13 lb in).
8. Install the air inlet assembly. 9. Install the evaporator case assembly.
10. Install the HVAC module.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13698
Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement
HVAC Module Assembly Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Disable the frontal and curtain air bags. 2. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging. 3. Drain the engine coolant. Refer to Cooling System Draining and
Filling (LNJ Static Fill) Cooling System Draining and Filling (LNJ GE 47716
Fill) Cooling System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7
GE 47716 Fill).
4. Remove the evaporator outlet hose and liquid line nut from the thermal expansion valve (TXV).
5. Remove the evaporator outlet hose from the TXV. 6. Remove and discard the sealing washer
from the evaporator outlet hose. 7. Remove the evaporator outlet hose and liquid line from the
TXV. 8. Remove and discard the sealing washer from the liquid line. 9. Install a protective caps to
the evaporator outlet hose and the liquid line to prevent contamination and desiccant saturation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13699
10. Reposition the heater outlet hose clamp at the heater core. 11. Remove the heater outlet hose
from the heater core (1). 12. Reposition the heater inlet hose clamp at the heater core (2). 13.
Remove the heater inlet hose at the heater core. 14. Plug the heater core and the evaporator core
with clean towels to prevent spillage when the HVAC module is removed.
15. Remove the HVAC module seal nuts from the front of dash. 16. Remove the instrument panel
(I/P) retainer. 17. Remove the shift control bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13700
18. Remove the center floor air outlet duct by sliding the duct forward then up at the rear.
19. Remove the center I/P air outlet duct retainers from the instrument panel tie bar. 20. Remove
the center I/P air outlet duct from the instrument panel tie bar. 21. Remove the instrument panel tie
bar. 22. Disconnect the blower motor electrical connector from the I/P wire harness. 23. Disconnect
the blower motor control module electrical connector from the I/P wire harness. 24. Disconnect the
HVAC module electrical connector from the I/P wire harness.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13701
25. Remove the defroster duct retainer from the instrument panel tie bar. 26. Remove the defroster
duct from the HVAC module. 27. Disconnect the I/P wire harness clips from the HVAC module.
28. Remove the HVAC module from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13702
Important: Make sure the HVAC module seals are flush and even as they meet their mating
surfaces. This will reduce the chance of leaks and ensure proper fit.
1. Inspect the front of dash seal for proper alignment. 2. Inspect the seal mating surfaces to ensure
there are no obstructions. 3. Position the HVAC module in the vehicle. 4. Install, but do not tighten,
the seal nuts to the front of dash. 5. Install the instrument panel tie bar.
Notice: Refer to Fastener Notice.
Important: New front of dash seal nuts must be used to prevent leaks.
6. Tighten the HVAC module seal nuts to the front of dash. Draw the HVAC module to the front of
dash evenly by alternating between the seal nuts.
Tighten the nuts to 8 N.m (71 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13703
7. Install the defroster duct to the HVAC module. 8. Install the defroster duct retainer to the
instrument panel tie bar. 9. Connect the I/P wire harness clips to the HVAC module.
10. Connect the blower motor electrical connector to the I/P wire harness. 11. Connect the blower
motor control module electrical connector to the I/P wire harness. 12. Connect the HVAC module
electrical connector to the I/P wire harness.
13. Install the center I/P duct to the instrument panel tie bar. 14. Install the center I/P duct retainers
to the instrument panel tie bar.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13704
15. Install the center floor air outlet by sliding forward onto the front floor air outlet then down and
rearward over the rear floor air outlet. 16. Install the shift control bracket. 17. Install the I/P retainer.
18. Install the heater inlet hose to the heater core (1). 19. Install the heater inlet hose clamp to the
heater core. 20. Install the heater outlet hose to heater core outlet (2). 21. Install the heater outlet
hose clamp to the heater core.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information >
Service and Repair > Blower Case Assembly Replacement > Page 13705
22. Ensure the mating surfaces are clean and free of debris, and install new seal washers to the
evaporator outlet hose and the liquid line. 23. Install the evaporator outlet hose and the liquid line to
the TXV. 24. Install the evaporator outlet hose and liquid line nut to the TXV.
Tighten the nut to 20 N.m (15 lb ft).
25. Enable the frontal and curtain air bags. 26. Fill the coolant. Refer to Cooling System Draining
and Filling (LNJ Static Fill) Cooling System Draining and Filling (LNJ GE 47716 Fill) Cooling
System Draining and Filling (LY7 Static Fill) Cooling System Draining and Filling (LY7 GE 47716
Fill).
27. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging. 28. Test
the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and
Repair
Receiver Dryer: Service and Repair
Receiver Dehydrator Replacement
Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the front
bumper fascia.
3. Remove the bolt retaining the receiver dehydrator mounting clamp to the condenser. 4. Remove
the receiver dehydrator mounting clamp from the condenser.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and
Repair > Page 13709
5. Remove the lower receiver dehydrator bolt from the condenser.
6. Remove the receiver dehydrator from the condenser. 7. Install protective caps to the condenser
to prevent contamination and desiccant saturation.
Installation Procedure
1. Remove the protective caps from the condenser. 2. Add the specified amount of polyalkylene
glycol (PAG) oil to the receiver dehydrator. Refer to Refrigerant System Capacities. 3. Install new
O-rings to the receiver dehydrator. 4. Install the receiver dehydrator to the condenser.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and
Repair > Page 13710
Notice: Refer to Fastener Notice.
5. Install the lower receiver dehydrator bolt to the condenser.
Tighten the bolt to 6.5 N.m (58 lb in).
6. Install the receiver dehydrator mounting clamp to the condenser. 7. Install the receiver
dehydrator mounting clamp bolt to the condenser.
Tighten the bolt to 4.2 N.m (37 lb in).
8. Install the front bumper fascia. 9. Evacuate and charge the A/C system. Refer to Refrigerant
Recovery and Recharging.
10. Test the affected A/C joints for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment
Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment
Bulletin No.: 08-01-38-001
Date: January 25, 2008
INFORMATION
Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment
Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and
Prior HUMMER H2, H3 2005-2008 Saab 9-7X
Attention:
This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C)
Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive
Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be
manufactured in its current state after December 2007 and will be superseded by GE-48800.
The new J2788 standard does not require that GM Dealers replace their ACR2000 units.
ACR2000's currently in use are very capable of servicing today's refrigerant systems when used
correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined
in GM Bulletin 07-01-38-004.
Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800)
will be released as a required replacement for the previously essential ACR2000 (J-43600). This
equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System
Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE)
refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships.
In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination
when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil.
The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush
Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50,
with installation instructions, as a component of the Hybrid essential tool package. Dealerships that
do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore.
Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure.
The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a
Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil.
This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.
Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C
compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It
may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost
Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be
voided.
Warranty Submission Requirements
The Electronically Generated Repair Data (snapshot summary) and printer functions have been
eliminated from the GE-48800. The VGA display and temperature probes were eliminated to
reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge
Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are
submitted for warranty reimbursement. The charge summary data from before and after system
repairs will continue to required, but documented on the repair order only. Both high and low
pressures and the recovery and charge amounts should be noted during the repair and entered on
the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should
continue to be attached to the shops copy of the repair order.
The labor codes that are affected by this requirement are D3000 through D4500.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications
Refrigerant: Capacity Specifications
Refrigerant System Capacities
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications > Page 13717
Refrigerant: Fluid Type Specifications
Refrigerant System Capacities
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Page 13718
Refrigerant: Service and Repair
Refrigerant Recovery and Recharging
Tools Required
* J 43600 ACR 2000 Air Conditioning Service Center
* J 45037 A/C Oil Injector
Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove
R-134a from the A/C system, use service equipment that is certified to meet the requirements of
SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the
work area before continuing service. Additional health and safety information may be obtained from
the refrigerant and lubricant manufacturers.
Caution: For personal protection, goggles and gloves should be worn and a clean cloth wrapped
around fittings, valves, and connections when doing work that includes opening the refrigerant
system. If R-134a comes in contact with any part of the body severe frostbite and personal injury
can result. The exposed area should be flushed immediately with cold water and prompt medical
help should be obtained.
Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.
Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through
the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure
is likely to occur. Refer to the manufacturer instructions included with the service equipment before
servicing.
The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers,
recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit
has a display screen that contains the function controls and displays prompts that will lead the
technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered
into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this
vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C
refrigerant.
The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to
recovery and will notify the technician if there are foreign gases present in the A/C system. If
foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.
The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.
Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the
A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the
correct amount.
A/C Refrigerant System Oil Charge Replenishing
If oil was removed from the A/C system during the recovery process or due to component
replacement, the oil must be replenished. Oil can be injected into a charged A/C system using J
45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant
System Capacities.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications
Refrigerant Oil: Specifications
PAG Oil GM P/N 12378526 for United States
PAG Oil GM P/N 88900060 for Canada
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low
Pressure Sensor / Switch, HVAC > Component Information > Service and Repair
Low Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Low Temperature Sensor Replacement
Removal Procedure
1. Remove the left side insulator/closeout panel. 2. If equipped with OnStar(R), remove the
communications interface module. 3. Disconnect the temperature sensor connector from the
temperature sensor. 4. Twist the temperature sensor one quarter turn to disengage from the
evaporator case assembly. 5. Remove the temperature sensor from the evaporator case assembly.
Installation Procedure
1. Install the temperature sensor to the evaporator case assembly. 2. Twist the temperature sensor
one quarter turn to engage to the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low
Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Page 13726
3. Install the temperature sensor connector to the temperature sensor. 4. If removed, install the
communications interface module. 5. Install the left side insulator/closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Compressor Clutch Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams
Control Module HVAC: Diagrams
Component Connector End Views
Blower Motor Control Processor - X1
Blower Motor Control Processor - X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 13734
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 13735
Control Module HVAC: Service and Repair
Blower Motor Control Module Replacement
Removal Procedure
1. Remove Right Lower Insulator Panel 2. Disconnect the electrical connector from the blower
motor control module. 3. Remove the blower control module screws from the HVAC module. 4.
Remove the blower motor control module from the HVAC module.
Installation Procedure
1. Install the blower motor control module to the HVAC module.
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 13736
2. Install the blower motor control module screws to the HVAC module.
Tighten the screws to 1.5 N.m (13 lb in).
3. Connect the electrical connector to the blower motor control module. 4. Install Right Lower
Insulator Panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature
Sensor / Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Front of Vehicle/Engine Compartment Component Views
Behind the Front Fascia Components
1 - Headlamp - Right 2 - Radiator 3 - Ambient Air Temperature Sensor (DH3/DF5)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature
Sensor / Switch HVAC > Component Information > Locations > Page 13741
Ambient Temperature Sensor / Switch HVAC: Diagrams
Component Connector End Views
Ambient Air Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature
Sensor / Switch HVAC > Component Information > Locations > Page 13742
Ambient Temperature Sensor / Switch HVAC: Service and Repair
Ambient Air Temperature Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
Instrument Panel/Center Console Component Views
Front HVAC Module Components
1 - Recirculation Actuator 2 - HVAC Blower Motor 3 - Blower Motor Control Processor 4 - Air
Temperature Actuator 5 - Mode Actuator 6 - Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations > Page 13746
Evaporator Temperature Sensor / Switch: Diagrams
Component Connector End Views
Evaporator Temperature Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair
Low Pressure Sensor / Switch: Service and Repair
Air Conditioning (A/C) Refrigerant Low Temperature Sensor Replacement
Removal Procedure
1. Remove the left side insulator/closeout panel. 2. If equipped with OnStar(R), remove the
communications interface module. 3. Disconnect the temperature sensor connector from the
temperature sensor. 4. Twist the temperature sensor one quarter turn to disengage from the
evaporator case assembly. 5. Remove the temperature sensor from the evaporator case assembly.
Installation Procedure
1. Install the temperature sensor to the evaporator case assembly. 2. Twist the temperature sensor
one quarter turn to engage to the evaporator case assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure
Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Page
13751
3. Install the temperature sensor connector to the temperature sensor. 4. If removed, install the
communications interface module. 5. Install the left side insulator/closeout panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and
Repair
Service Port HVAC: Service and Repair
Air Conditioning Refrigerant Service Valve Core Replacement
Tools Required
* J 39400-A Halogen Leak Detector
* J 46246 Valve Core Removal Tool
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Use J 46246 or equivalent to remove the valve core.
Installation Procedure
1. Use J 46246 or equivalent to install and tighten the valve core. 2. Evacuate and charge the A/C
system. Refer to Refrigerant Recovery and Recharging.
Important: To prevent loss of refrigerant charge, tighten the cap. Replace the cap if the seal is
missing or damaged.
3. Test the affected A/C fittings for leaks using J 39400-A.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts
Repairs and Inspections Required After a Collision: Service and Repair Seat Belts
Repairs and Inspections Required After a Collision
Caution: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all
parts in need of replacement are replaced:
* Replace any seat belt system that was in use during the collision serious enough to deploy any
automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat
belt systems in use by people of adult size, but seat belt systems used to secure child restraints,
infant carriers and booster seats, including LATCH system and top tether anchorages.
* Replace any seat belt system that has torn, worn, or damaged components. This not only
includes adult seat belt systems, but built-in child restraints and LATCH system components, if any.
* Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow
tag is visible. Do not replace a seat belt if only the child seat caution label is visible.
* Replace any seat belt system if you are doubtful about its condition. This not only includes adult
seat belt systems, but built-in child restraints, LATCH system components, and any restraint
system used to secure infant carriers, child restraints, and booster seats.
Do NOT replace single seat belt system components in vehicles that have been in a collision as
described above. Always replace the entire seat belt system with the buckle, guide and retractor
assembly, which includes the latch and webbing material.
After a minor collision where no automatic restraint device was deployed, seat belt system
replacement may not be necessary unless some of the parts are torn, worn, or damaged.
After any collision, verify that the pretentioners on the front seat belt retractor have not deployed.
1. Pull the seat belt webbing. 2. If you hear a grinding or a rattling, replace the retractor.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts > Page 13760
Repairs and Inspections Required After a Collision: Service and Repair Steering Column
Steering Column Accident Damage Inspection
Inspection
This vehicle is equipped with electric power steering (EPS), with the electric motor and torque
sensor mounted on the steering column. When involved in an accident resulting in sheet metal
damage or driver-side air bag deployment, the steering column must be inspected for both
electrical system integrity and steering column collapse. Refer to Diagnostic System Check Vehicle See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System
Check - Vehicle .
* If the steering column electrical system integrity is not within specifications, the complete steering
column must be replaced. Refer to Steering Column Replacement (with EPS) (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Wheel and Column/Steering
Column Replacement (with EPS))Steering Column Replacement (with HPS) (See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Steering Wheel and Column/Steering
Column Replacement (with HPS)) .
* If the steering column collapse mechanism is not within specifications, but the electrical system
integrity is within specifications, then the steering column upper jacket must be replaced. Refer to
Steering Column Jacket Replacement (See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Jacket Replacement) .
Road test the vehicle when ever any steering system repairs or diagnostics have been performed.
Electric Power Steering (EPS) Inspection
1. Install a scan tool. 2. Start the engine.
Important: After centering the steering wheel, remove hands and other objects from the steering
wheel. Ensure the suspension is relaxed and that no bias, or uneven force is being applied to the
steering system.
3. Turn the steering wheel 90 degrees to the left, then 90 degrees to the right, then return the
steering wheel to center. 4. Using the scan tool, observe the Torque Sensor Main data parameter in
the EPS data list. Correct parameter range for the torque sensor is <+ or - 1
N.m (0.7 lb ft).
5. If the value is greater than the specified range then replace the steering column assembly. Refer
to Steering Column Replacement (with EPS) (See:
Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel and
Column/Steering Column Replacement (with EPS) )Steering Column Replacement (with HPS)
(See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel and
Column/Steering Column Replacement (with HPS)) .
Collapse Measurement
A vehicle involved in an accident resulting in sheet metal damage or drivers-side air bag
deployment will require an inspection for steering column collapse. If the steering column collapse
measurement is greater than 3 mm than the steering column upper jacket must be replaced.
For steering column collapse measurement, use the following procedure:
1. Remove the steering column trim covers. Refer to Steering Column Trim Covers Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Covers Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts > Page 13761
2. Inspect the upper steering column mounting capsule nuts for movement (a). If the steering
column collapse measurement is greater than 3 mm than
the steering column upper jacket must be replaced. Refer to Steering Column Jacket Replacement
(See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column
Jacket Replacement) .
3. Install the steering column trim covers. Refer to Steering Column Trim Covers Replacement
(See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Steering Column Trim Covers Replacement) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System
Information > Service and Repair > Seat Belts > Page 13762
Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable
Restraints
Repairs and Inspections Required After a Collision
Accident With or Without Air Bag Deployment - Component Inspections
Caution: Proper operation of the SIR sensing system requires that any repairs to the vehicle
structure return the vehicle structure to the original production configuration. Not properly repairing
the vehicle structure could cause non-deployment in a collision or deployment for conditions less
severe than intended.
After a collision, inspect the following components as indicated. If any damage is detected, replace
the component. If damage to the mounting points or mounting hardware is detected, repair the
component or replace the hardware as needed.
* Steering column-Perform the steering column accident damage checking procedures. Refer to
Steering Column Accident Damage Inspection. See: Steering Column
* Instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending,
twisting, buckling, or any other type of damage.
* I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage.
* Seat belts-Perform the seat belt operational and functional checks. Refer to Operational and
Functional Checks. See: Seat Belt Systems/Testing and Inspection/Initial Inspection and
Diagnostic Overview/Operational and Functional Checks
* Seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of
damage.
* Passenger seat bottom with passenger presence system (PPS)-Check for any dtcs or problems
that may cause the PPS not to function properly.
* The roof and headliner mounting points.
Frontal Inflator Module Deployment
After a collision involving air bag deployment, replace the following components.
Important: The front passenger seat is equipped with a PPS, which detects an occupant. If the
requirements for disabling the I/P air bag are met then the PPS will communicate with the sensing
and diagnostic module (SDM) to disable/turn OFF the I/P air bag, even in a accident. For more
information on the PPS refer to SIR System Description and Operation.
* Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed
above
* Inflatable restraint steering wheel module
* Inflatable restraint SDM
* Inflatable restraint front end sensor, left/right
* Inflatable restraint seat belt pretensioners
Perform additional inspections on the following components.
* Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other
damage due to excessive heat.
* Mounting points or mounting hardware for the I/P, steering wheel module, SDM, and
pretensioners-Inspect for any damage and repair or replace each component as needed.
Accident With Side Air Bag Deployment - Component Replacement and Inspections
After a collision involving side air bag deployment, replace the following components.
* Inflatable restraint side impact sensors (SIS), left/right, on the side of the impact
* Inflatable restraint roof rail module, left/right, on the side of the impact
* Inflatable restraint SDM
* Inflatable restraint seat belt pretensioner
Perform additional inspections on the following components.
* Mounting points or mounting hardware for the SIS-Inspect for any damage and repair or replace
each component as needed.
* Mounting points or mounting hardware for the roof rail module (left/right) on the side of
impact-Inspect for any damage and repair or replace each component as needed.
* Mounting points or mounting hardware for the SDM and seat belt pretensioners-Inspect for any
damage and repair or replace each component as needed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Page 13767
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints
- Air Bag Lamp ON/Multiple DTC Set
Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints
- Air Bag Lamp ON/Multiple DTC Set > Page 13777
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints
- Air Bag Lamp ON/Multiple DTC Set > Page 13778
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10
> Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10
> Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13784
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10
> Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13785
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air
Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air
Bag Lamp ON/Multiple DTC Set > Page 13794
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air
Bag Lamp ON/Multiple DTC Set > Page 13795
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D > Dec > 07 > Restraints Airbag Light On/DTC B0081 Set
Air Bag Control Module: Customer Interest Restraints - Airbag Light On/DTC B0081 Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D > Dec > 07 > Restraints Airbag Light On/DTC B0081 Set > Page 13800
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 >
Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC
Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 >
Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13806
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 >
Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13807
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-41-006D > Dec > 07 >
Restraints - Airbag Light On/DTC B0081 Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Airbag Light On/DTC B0081
Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 06-09-41-006D > Dec > 07 >
Restraints - Airbag Light On/DTC B0081 Set > Page 13812
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13813
Air Bag Control Module: Locations
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13814
Air Bag Control Module: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Sensing and Diagnostic Module (SDM) (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13815
Inflatable Restraint Sensing and Diagnostic Module (SDM) (-ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13816
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13817
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13818
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 13819
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures
Clockspring Assembly / Spiral Cable: Procedures
Inflatable Restraint Steering Wheel Module Coil Centering
Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly
may damage the unit, causing an inflatable restraint malfunction.
1. Verify the following conditions before centering the supplemental inflatable restraint (SIR)
steering wheel module coil:
* The wheels on the vehicle are straight ahead.
* The block tooth and the centering mark (1) of the steering shaft is in the 12 o'clock position.
2. If available, remove the yellow retaining tab (1) from the SIR steering wheel module coil and
save the tab for reassembly. 3. Hold the SIR steering wheel module coil face up by the casing (2).
1. Slowly turn the SIR steering wheel module coil hub (3) clockwise until the coil ribbon stops. 2.
Slowly rotate the SIR steering wheel module coil hub (3) counterclockwise 2.5 revolutions until the
centering window (4) turns yellow. This
indicates the CENTER position.
Important: If the retaining tab is not available, the use of tape to secure the SIR steering wheel
module coil is recommended for installation to the steering column.
4. Install the yellow retaining tab (1) to the SIR steering wheel module coil. 5. Slide the centered
SIR steering wheel module coil onto the steering shaft.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures > Page 13824
Clockspring Assembly / Spiral Cable: Removal and Replacement
Inflatable Restraint Steering Wheel Module Coil Replacement
Removal Procedure
Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly
may damage the unit, causing an inflatable restraint malfunction.
1. Place the front wheels in the straight forward position with the steering wheel centered. 2.
Disable the SIR system. Refer to SIR Disabling and Enabling. 3. Remove the inflatable restraint
steering wheel module. 4. Remove the steering wheel. 5. Remove the steering column covers.
6. Release the SIR coil harness clips from the bracket below the column. 7. Disconnect both the
SIR coil and horn/cruise connectors. 8. Using a small flat-bladed tool, carefully pry the retaining
tabs away from the SIR coil assembly and slide the SIR coil assembly off the steering
column.
Installation Procedure
Important: A new roll connector is equipped with a yellow tab that is removed after the steering
wheel is installed. This tab passes through the steering wheel.
1. Route the SIR wiring harness and horn/cruise connector down steering column.
2. Snap the SIR coil into position on the column. 3. Connect the SIR coil and horn/cruise electrical
connectors. 4. Attach the wiring harness clips to the bracket below the column.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service and Repair > Procedures > Page 13825
5. Install the steering column covers. 6. Install the steering wheel. 7. Install the inflatable restraint
steering wheel module. 8. Enable the SIR system. Refer to SIR Disabling and Enabling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Passenger Compartment/Roof Component Views
Impact Sensor: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Passenger Compartment/Roof Component Views > Page 13830
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Core Support Components
1 - Inflatable Restraint Front End Sensor - Left 2 - Radiator Core Support 3 - Cooling Fan - Right 4
- Cooling Fan - Left
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 13831
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left (-ASF)
Inflatable Restraint Front End Sensor - Right (-ASF)
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 13832
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Rollover Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Locations > Page 13833
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13836
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13837
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13838
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Technical Service Bulletins > Customer Interest for Seat Occupant Classification Module - Air
Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: Customer Interest Restraints - AIr Bag Lamp
ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification
Module - Air Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Restraints - AIr Bag
Lamp ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Page 13856
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Technical Service Bulletins > Page 13857
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Diagrams
Malfunction Lamp / Indicator: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Passenger Air Bag ON/OFF Indicator
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Diagrams > Page 13861
Malfunction Lamp / Indicator: Service and Repair
Inflatable Restraint Instrument Panel Module Indicator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service
Bulletins > Restraints - Driver/Passenger Seat Head Rest Information
Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest
Information
INFORMATION
Bulletin No.: 10-08-50-003A
Date: March 24, 2011
Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom
Upholstery or Other Comfort Enhancing Devices
Models:
2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 10-08-50-003 (Section 08 - Body and Accessories).
Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE
HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS
RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD
RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED
DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE
OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS
INCURRED.
You may have a customer with a concern that the head restraint is uncomfortable or sits too far
forward. The front driver and passenger seats are equipped with head restraints that have been
designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle
has its own specifically designed head restraint.
The head restraints should only be used in the vehicle for which they were designed. The head
restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or
head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or
head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket
comfort enhancing pad or device, is installed.
Never modify the design of the head restraint or remove the head restraint from the vehicle as this
may interfere with the operation of the seating and restraint systems and may prevent proper
positioning of the passenger within the vehicle.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair
Knee Diverter: Service and Repair
Driver Knee Bolster Reinforcement Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13878
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F >
Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13879
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D >
Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set
Air Bag Control Module: Customer Interest Restraints - Airbag Light On/DTC B0081 Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 06-09-41-006D >
Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set > Page 13884
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC
Set
TECHNICAL
Bulletin No.: 08-09-41-002F
Date: June 10, 2010
Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent
AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020,
B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector
Position Assurance (CPA) Retainer)
Models:
2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010
Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac
SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet
TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo
2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009
Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010
Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC
Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana
2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac
G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK,
SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel
GT
Supercede: This bulletin is being revised to update the Warranty Information and add Saab
Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints).
Condition
- Some customers may comment on an intermittent or current AIR BAG indicator or lamp being
illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the
following DTCs:
- Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E;
B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D,
0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic
module (SDM).
Cause
This condition may be caused by a loose, missing, or damaged connector position assurance
(CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a
deployment loop wiring harness electrical connector.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13890
Caution
When performing service on or near the SIR components or the SIR wiring, the SIR system must
be disabled. Failure to observe the correct procedure could cause deployment of the SIR
components. Serious injury can occur. Failure to observe the correct procedure could also result in
unnecessary SIR system repairs.
1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the
DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code
(DTC)
List-Vehicle in SI.
3. Using the information from the DTC Descriptor, determine the location of the affected electrical
connector. Refer to SIR Identification Views and
the Master Electrical Component List in SI.
4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to
SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the
electrical connector.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one.
Reinstall the CPA correctly by first pushing
the connector body in completely, and then pushing the CPA retainer in completely.
‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6.
6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the
following conditions:
- Corrosion
- Contamination
- Terminal tension
- Damage
Important The terminals in the SIR/SRS system are made with a special plating. This plating
provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125
SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute
any other terminals for those in the repair kit.
‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as
necessary. Apply dielectric grease, GM P/N
12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when
reassembling. Refer to SIR/SRS Wiring Repairs in SI.
Note The connector and connector position assurance (CPA) may seat independent of each other.
Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the
shorting-bars within the connector allowing the deployment circuit to operate properly.
7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental
inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a
scan tool.
10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI.
‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI.
Parts Information
Note
If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS
terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of
5.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13891
Warranty Information (excluding Saab U.S. Models)
Important Select the appropriate Labor Operation for the repair that is performed.
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
06-09-41-006D > Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set
Air Bag Control Module: All Technical Service Bulletins Restraints - Airbag Light On/DTC B0081
Set
Bulletin No.: 06-09-41-006D
Date: December 13, 2007
TECHNICAL
Subject: Airbag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Supercede:
This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin
Number 06-09-41-006C (Section 09 - Restraints).
Condition
Some customers may comment on the airbag light being illuminated. Upon investigation, the
technician may find DTC B0081 with symptom code 0F or 5A set.
Cause
This condition may be caused by a low state of charge or a dead battery in the vehicle.
Correction
The code can be cleared using the following procedure. Once the code is cleared, the airbag light
will go out. Key ON and engine OFF.
Use the scan tool to perform the Re-Zero Passenger Presence System within the Module Setup of
the Passenger Presence System (PPS).
After all procedures have been successfully completed, retrieve the DTCs from PPS and clear all
the DTCs.
Verify that the airbag light is no longer illuminated.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: >
06-09-41-006D > Dec > 07 > Restraints - Airbag Light On/DTC B0081 Set > Page 13896
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13897
Air Bag Control Module: Locations
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13898
Air Bag Control Module: Diagrams
Component Connector End Views - Continued
Inflatable Restraint Sensing and Diagnostic Module (SDM) (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13899
Inflatable Restraint Sensing and Diagnostic Module (SDM) (-ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13900
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13901
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13902
Air Bag Control Module: Service and Repair
Inflatable Restraint Sensing and Diagnostic Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 13903
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Seat
Occupant Classification Module - Air Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: Customer Interest Restraints - AIr Bag Lamp
ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Seat Occupant Classification Module - Air Bag: > 08-09-41-004 > Mar > 08 > Restraints - AIr Bag Lamp ON/DTC B1000 Set
Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Restraints - AIr Bag
Lamp ON/DTC B1000 Set
TECHNICAL
Bulletin No.: 08-09-41-004
Date: March 12, 2008
Subject: Airbag Light On, DTC B1000 Set (Reprogram Passenger Presence System (PPS)
Module)
Models: 2008 Buick Enclave 2005-2008 Cadillac SRX 2005-2008 Chevrolet Equinox 2007-2008
GMC Acadia 2006-2008 Pontiac Torrent 2007-2008 Saturn OUTLOOK 2007-2008 Suzuki XL-7
Condition
Some customers may comment on the airbag light being illuminated.
Upon investigation, the technician may find DTC B1000 with symptom code 37 set as current or in
history.
Correction
Important:
You must contact Techline to obtain a VCI number.
New software for the Passenger Presence System (PPS) has been released to disable this
diagnostic check to prevent false setting of DTC B1000. Reprogram the PPS module with updated
calibration files using the TIS2WEB Service Programming System (SPS) application. As always,
make sure your Tech 2(R) is updated with the latest software version.
Perform a PPS rezero/preload procedure upon a successful module reprogramming event.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Page 13921
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service and Repair
Child Seat Tether Attachment: Service and Repair
Child Restraint Tether Anchor Bezel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions
Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions
INFORMATION
Bulletin No.: 05-09-40-002E
Date: October 21, 2010
Subject: Safety Belt Locking Conditions (Normal Operating Characteristic)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 05-09-40-002D (Section 09 - Restraints).
The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are
several different locking situations for both front and rear safety belts.
Overspool Lock
There is an unintentional locking condition that ALL safety belts from ALL manufacturers may
experience called "overspool lock". If the webbing snaps back to the stowed position rapidly
enough, the retractor will lock with the belt fully stowed. This is more likely to occur when
customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the
retractive speed of the webbing, the higher than normal webbing retraction speed that occurs
engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the
webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the
locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT
replace the retractor for this condition until first attempting to disengage the locking mechanism by
following the recommendation listed below.
Recommendation
Pull hard on the locked webbing and then release. The hard pull extracts a small amount of
webbing from the retractor which, in turn, permits a small amount of retraction to occur when
released. This is all that is needed to disengage the locking mechanism. The safety belt will now
function properly.
Vehicle Sensing
This type of locking occurs in response to the vehicle under the following conditions:
- The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR
rapid deceleration or there is aggressive cornering).
- It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or
side-to-side), such as streets in San Francisco, California.
- It may also occur over rough road conditions where the retractor mechanism is bounced into a
locked condition.
In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked.
When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt
should return to normal function. Please inform customers that may comment that "the belt locks
intermittently" that this is the design intent and the belt is functioning properly.
Web Sensing
This type of locking occurs in response to the extraction of webbing. When the webbing reels out at
an accelerated rate, it goes into lock mode and stays there until tension is again released. To
observe this condition, extract the webbing quickly. Customers may refer to this condition as
"intermittent lock-up" and encounter it when trying to put the belt on too quickly.
Automatic Locking (ALR)
When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down
mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers
may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to
the end of travel while they are putting the belt on. The ALR mode of operation is automatically
cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function).
Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only,
as a unique feature. Corvette customers may find this feature appealing when they plan to operate
the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the
operator is snugly cinched into the seat and kept firmly in place during high G-force driving
maneuvers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 13930
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Quick Connect)
Seat Belt: Service and Repair Front Seat Belt Replacement (Quick Connect)
Front Seat Belt Replacement (Quick Connect)
Removal Procedure
1. Using a small flat-bladed tool, depress the button on the seat buckle quick disconnect feature
while pulling up on the shoulder belt to disengage the
shoulder belt from the front seat assembly.
2. Remove the lower garnish molding from the center pillar.
3. Remove the retractor fastener and remove the retractor. 4. Remove the shoulder belt webbing
retainer by pulling on the retainer while using a flat-bladed tool to disengage the attaching clips. 5.
Remove the shoulder belt from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Quick Connect) > Page 13933
Important: Apply GM P/N 12345382 (Canadian P/N 10953489), Permatex(R) 24200 or equivalent
on all restraint fasteners prior to installation.
1. Position the shoulder belt retractor into the center pillar positioning unit with the locking tab in the
body structure notch.
Notice: Refer to Fastener Notice.
2. Install the retractor fastener.
Tighten the fastener to 45 N.m (33 lb ft).
3. Snap the shoulder belt webbing retainer into the center pillar. 4. Install the lower garnish molding
into the center pillar.
5. Install the seat belt to the seat assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Quick Connect) > Page 13934
Seat Belt: Service and Repair Seat Belt Latch Stop Installation
Seat Belt Latch Stop Installation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Quick Connect) > Page 13935
Seat Belt: Service and Repair Seat Belt Replacement - Center Rear
Seat Belt Replacement - Center Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Front Seat Belt Replacement (Quick Connect) > Page 13936
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning
Lamp On/Buckling Issues
Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling
Issues
INFORMATION
Bulletin No.: 09-09-40-001A
Date: February 02, 2011
Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7 X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-09-40-001 (Section 09 - Restraints).
This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat
belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle
release button sticking.
Analysis of warranty data has determined that this condition may be caused by sticky beverages
being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers,
paper and coins can also contribute to this condition.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced. Point out the
fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the
customer declines to have parts replaced, the service department management must make a
notation on the service record that the lack of functionality of seating position with an inoperative
buckle was fully explained to the customer. The service department management must advise the
customer that having a non-functioning buckle in a seating position voids ability to use that seating
position (no one should ride in the seat). Also make the customer aware that it may be against the
law to ride in a vehicle without wearing a restraint system.
Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do
not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a
spilled liquid as this may damage the buckle.
Use the following steps to determine the cause of the concern.
1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any
debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to
vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If
the system functions properly, do not replace the seat belt buckle assembly.
3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If
sticky residue is found, inform the customer that a
substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle
assembly will need to be replaced at the customer's expense.
4. Refer to SI for seat belt component replacement.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced at the
customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by
the new vehicle warranty. If the customer declines to have parts replaced, the service department
management must make a notation on the service record that the lack of functionality of seating
position with an inoperative buckle was fully explained to the customer. The service department
management must advise customer that having a non-functioning buckle in a seating position voids
ability to use that seating position (no one should ride in the seat). Also make the customer aware
that it may be against the law to ride in a vehicle without wearing a restraint system.
5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional
Checks in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning
Lamp On/Buckling Issues > Page 13945
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 07-09-40-002A > Jun > 09 > Restraints - Seat Belt Latch
Stop Button Availability
Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button
Availability
INFORMATION
Bulletin No.: 07-09-40-002A
Date: June 04, 2009
Subject: Seat Belt Latch Stop Button Available for Service
Models:
2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2
2006-2010 HUMMER H3 2009-2010 HUMMER H3T
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002
(Section 09 - Restraints).
..............................................................................................................................................................
..................................................................................
All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the
button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat
belt retractor assembly does not need replacement.
Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation
procedure.
Parts Information
For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp
On/Buckling Issues
Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues
INFORMATION
Bulletin No.: 09-09-40-001A
Date: February 02, 2011
Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7 X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 09-09-40-001 (Section 09 - Restraints).
This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat
belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle
release button sticking.
Analysis of warranty data has determined that this condition may be caused by sticky beverages
being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers,
paper and coins can also contribute to this condition.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced. Point out the
fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the
customer declines to have parts replaced, the service department management must make a
notation on the service record that the lack of functionality of seating position with an inoperative
buckle was fully explained to the customer. The service department management must advise the
customer that having a non-functioning buckle in a seating position voids ability to use that seating
position (no one should ride in the seat). Also make the customer aware that it may be against the
law to ride in a vehicle without wearing a restraint system.
Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do
not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a
spilled liquid as this may damage the buckle.
Use the following steps to determine the cause of the concern.
1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any
debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to
vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If
the system functions properly, do not replace the seat belt buckle assembly.
3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If
sticky residue is found, inform the customer that a
substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle
assembly will need to be replaced at the customer's expense.
4. Refer to SI for seat belt component replacement.
Important If foreign material (debris) or sticky liquids are the cause of the concern, show the
customer the condition of the component (buckle assembly) and explain how it is affecting the
function of the restraint system. Strongly recommend that the component be replaced at the
customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by
the new vehicle warranty. If the customer declines to have parts replaced, the service department
management must make a notation on the service record that the lack of functionality of seating
position with an inoperative buckle was fully explained to the customer. The service department
management must advise customer that having a non-functioning buckle in a seating position voids
ability to use that seating position (no one should ride in the seat). Also make the customer aware
that it may be against the law to ride in a vehicle without wearing a restraint system.
5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional
Checks in SI.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp
On/Buckling Issues > Page 13955
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information
Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair
Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13961
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13962
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13963
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 00-08-48-005D > Sep > 10 > Body - Vehicle
Glass Distortion Information
Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13973
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13974
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 03-08-48-006H > Apr > 11 > A/C - Window
Defroster Contact/Tab Repair Information > Page 13975
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Front Seat Belt Buckle Replacement
Seat Belt Buckle: Service and Repair Front Seat Belt Buckle Replacement
Front Seat Belt Buckle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Service and Repair > Front Seat Belt Buckle Replacement > Page 13982
Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement
Rear Seat Center Belt Buckle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component
Information > Locations
Seat Belt Buckle Switch: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Power Driver Seat Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component
Information > Locations > Page 13986
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component
Information > Locations > Page 13987
Seat Belt Buckle Switch: Diagrams
Component Connector End Views - Continued
Seat Belt Switch - Left
A/T Shift Lock Control Solenoid
Seat Belt Switch - Right
A/T Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Technical Service Bulletins > Restraints - Extender Availability For Seat Belt
Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt
INFORMATION
Bulletin No.: 99-09-40-005F
Date: June 23, 2010
Subject: Seat Belt Extender Availability
Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X
Supercede:
This bulletin is being revised to add the 2009‐2011 model years and update the Warranty
Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints).
Important:
DO NOT use belt extenders when securing a child restraint.
The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient
belt length to accommodate most drivers and passengers. Consequently, requests for belt
extensions (extenders) should be minimal.
Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks
produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15
in). They are designed to be coupled with the existing belts in each vehicle. When in use, the
extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle
will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is
extremely important that the correct length extender be used for the vehicle and occupant intended.
Important:
Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when
you cannot buckle the safety belt without using an extender.
Parts Information
For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact
the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada.
Warranty Information
^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their
specific vehicles.
^ Dealers should not be charging part costs since these extenders are supplied by GM to the
dealers.
^ Dealers should not be charging labor costs since the extender can be customer installed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information
> Service and Repair
Seat Belt Guide Track: Service and Repair
Guide Replacement - Rear Seat Shoulder Belt
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component
Information > Service and Repair
Seat Belt Height Adjuster: Service and Repair
Seat Belt Height Adjuster Replacement - Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions
Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking
Conditions
INFORMATION
Bulletin No.: 05-09-40-002E
Date: October 21, 2010
Subject: Safety Belt Locking Conditions (Normal Operating Characteristic)
Models:
2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER
H2, H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 05-09-40-002D (Section 09 - Restraints).
The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are
several different locking situations for both front and rear safety belts.
Overspool Lock
There is an unintentional locking condition that ALL safety belts from ALL manufacturers may
experience called "overspool lock". If the webbing snaps back to the stowed position rapidly
enough, the retractor will lock with the belt fully stowed. This is more likely to occur when
customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the
retractive speed of the webbing, the higher than normal webbing retraction speed that occurs
engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the
webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the
locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT
replace the retractor for this condition until first attempting to disengage the locking mechanism by
following the recommendation listed below.
Recommendation
Pull hard on the locked webbing and then release. The hard pull extracts a small amount of
webbing from the retractor which, in turn, permits a small amount of retraction to occur when
released. This is all that is needed to disengage the locking mechanism. The safety belt will now
function properly.
Vehicle Sensing
This type of locking occurs in response to the vehicle under the following conditions:
- The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR
rapid deceleration or there is aggressive cornering).
- It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or
side-to-side), such as streets in San Francisco, California.
- It may also occur over rough road conditions where the retractor mechanism is bounced into a
locked condition.
In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked.
When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt
should return to normal function. Please inform customers that may comment that "the belt locks
intermittently" that this is the design intent and the belt is functioning properly.
Web Sensing
This type of locking occurs in response to the extraction of webbing. When the webbing reels out at
an accelerated rate, it goes into lock mode and stays there until tension is again released. To
observe this condition, extract the webbing quickly. Customers may refer to this condition as
"intermittent lock-up" and encounter it when trying to put the belt on too quickly.
Automatic Locking (ALR)
When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down
mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers
may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to
the end of travel while they are putting the belt on. The ALR mode of operation is automatically
cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function).
Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only,
as a unique feature. Corvette customers may find this feature appealing when they plan to operate
the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the
operator is snugly cinched into the seat and kept firmly in place during high G-force driving
maneuvers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 14002
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 14003
Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability
INFORMATION
Bulletin No.: 07-09-40-002A
Date: June 04, 2009
Subject: Seat Belt Latch Stop Button Available for Service
Models:
2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2
2006-2010 HUMMER H3 2009-2010 HUMMER H3T
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002
(Section 09 - Restraints).
..............................................................................................................................................................
..................................................................................
All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the
button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat
belt retractor assembly does not need replacement.
Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation
procedure.
Parts Information
For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or
Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the
appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Seat Belt Retractor Anchor Plate Replacement
Seat Belt Retractor: Service and Repair Seat Belt Retractor Anchor Plate Replacement
Seat Belt Retractor Anchor Plate Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Seat Belt Retractor Anchor Plate Replacement > Page 14006
Seat Belt Retractor: Service and Repair Rear Seat Belt Replacement
Rear Seat Belt Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams
Seat Belt Tensioner: Diagrams
Component Connector End Views - Continued
Seat Belt Pretensioner - Left
Seat Belt Pretensioner - Right
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 14010
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures
Seat Belt Tensioner: Procedures
Pretensioner Handling and Scrapping
Caution: When carrying an undeployed inflatable restraint seat belt retractor pretensioner:
* Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped.
* Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat
belt webbing.
* Make sure the opening, from which the seat belt webbing extends, faces downward and the seat
belt webbing hangs freely.
Failure to observe these guidelines may result in personal injury.
Scrapping Procedure
During the course of a vehicles useful life, certain situations may arise which will require the
disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and
undeployed seat belt pretensioner through normal disposal channels until the seat belt
pretensioner has been deployed. The following information covers the proper procedures for
disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor
pretensioner in the following situations:
* After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor
pretensioner may need to be returned undeployed to the manufacturer.
* If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the
seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat
belt system in any manner.
* If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the
instructions in the Campaign Service Bulletin for proper SIR handling procedures.
Deployment Procedures
The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used
depends upon the final disposition of the vehicle. Review the following procedures in order to
determine which will work best in a given situation.
Deployment Inside the Vehicle
Refer to Inflator Module Handling and Scrapping for deploying the pretensioner inside vehicle
under Vehicle Scrapping Procedure.
Deployment Outside Vehicle for Seat Belt Pretensioners
Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to
service. Situations that require deployment outside of the vehicle include the following:
* Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning.
* The seat belt pretensioner pigtail, if equipped, is damaged.
* The seat belt retractor pretensioner connector is damaged.
* The seat belt retractor pretensioner connector terminals are damaged.
Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required
retention period.
Caution: In order to prevent accidental deployment and the risk of personal injury, do not dispose of
an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat
belt pretensioners contain substances that could cause severe illness or personal injury if their
sealed containers are damaged during disposal. Use the following deployment procedures to safely
dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods
may be a violation of federal, state, or local laws.
Tools Required
* J 38826 SIR Deployment Harness
* J 38826-25 for seat belt pretensioner module adapter
* J 39401-B SIR Deployment Fixture
* An appropriate pigtail adaptor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 14013
1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat
belt retractor pretensioner from the vehicle. 5. When carrying a seat belt retractor pretensioner to
the deployment area, keep fingers clear of the seat belt webbing.
6. Clear a space on the ground about 1.85 m (6 ft) in diameter (a) for deployment of the seat belt
pretensioner. If possible, use a paved, outdoor
location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you
have sufficient ventilation.
7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of
the cleared area. 9. Fill the fixture plastic reservoir with water or sand.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 14014
10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing
up using the following mounting method.
* Adjust and secure the J 39401-B arms (4) to the deployment fixture, with the short slotted
portions of the arms standing vertically and facing toward the center of the deployment fixture.
* To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt
pretensioner (1) to the deployment fixture brackets.
* Securely tighten all fasteners prior to deployment.
11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12.
Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other.
13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the
SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the
seat belt pretensioner connector to the adapter on the deployment harness.
Important: When deploying a seat belt retractor pretensioner, the rapid expansion of gas is very
loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 14015
16. Clear the area of people.
17. Separate the 2 banana plugs on the SIR deployment harness.
Important: When the seat belt retractor pretensioner deploys, the deployment fixture may jump
about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force
of the rapid expansion of gas inside the pretensioner.
18. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted
end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt
pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment
harness from the power source after the seat belt retractor pretensioner deploys.
21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the
seat belt retractor pretensioner did not deploy, disconnect the adapter and discontinue the
procedure. Contact the Technical Assistance
Group. Otherwise, proceed to the following steps.
23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt retractor
pretensioner as soon as possible. 25. Dispose of the deployed seat belt retractor pretensioner
through normal refuse channels. 26. Wash hands with a mild soap.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 14016
Seat Belt Tensioner: Removal and Replacement
Seat Belt Retractor Pretensioner Replacement - Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Procedures > Page 14017
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Passenger Compartment/Roof Component Views
Impact Sensor: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Center Floor Pan Components
1 - Floor Panel 2 - Console 3 - Yaw Rate and Lateral Acceleration Sensor 4 - Seat Belt
Pretensioner - Right 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF) 6 - Rollover
Sensor (ASF) 7 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 8 - Seat Belt
Pretensioner - Left 9 - Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 14023
Impact Sensor: Locations Front of Vehicle/Engine Compartment Component Views
Front of Vehicle/Engine Compartment Component Views
Core Support Components
1 - Inflatable Restraint Front End Sensor - Left 2 - Radiator Core Support 3 - Cooling Fan - Right 4
- Cooling Fan - Left
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 14024
Impact Sensor: Diagrams
Component Connector End Views
Inflatable Restraint Front End Sensor - Left (-ASF)
Inflatable Restraint Front End Sensor - Right (-ASF)
Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 14025
Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
Rollover Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 14026
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement
Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement
Inflatable Restraint Front End Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14029
Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement
Inflatable Restraint Vehicle Rollover Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14030
Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14031
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch
> Component Information > Locations
Seat Belt Buckle Switch: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Power Driver Seat Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch
> Component Information > Locations > Page 14035
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch
> Component Information > Locations > Page 14036
Seat Belt Buckle Switch: Diagrams
Component Connector End Views - Continued
Seat Belt Switch - Left
A/T Shift Lock Control Solenoid
Seat Belt Switch - Right
A/T Shift Lock Control Solenoid
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information
Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System
Information
INFORMATION
Bulletin No.: 06-08-50-009F
Date: December 23, 2010
Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With
Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing
System
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories).
Concerns About Safety and Alterations to the Front Passenger Seat
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT
VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY
ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN
OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF
SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED.
The front passenger seat in many GM vehicles is equipped with a passenger sensing system that
will turn off the right front passenger's frontal airbag under certain conditions, such as when an
infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the
right front passenger's seat mounted side impact airbag. For the system to function properly,
sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger
sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers,
upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by
GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an
aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or
between the occupant and the seat fabric.
Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices
Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY
SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM
ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR
SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE
APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH
IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE
NECESSARY BY SUCH USE.
Many types of aftermarket accessories are available to customers, upfitting shops, and dealers.
Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat
heaters are installed under the seat fabric. Additionally, seat covers made of leather or other
materials may have different padding thickness installed that could prevent the Passenger Sensing
System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to
the seat cushion, as this may interfere with the operation of the Passenger Sensing System and
either prevent proper deployment of the passenger airbag or prevent proper suppression of the
passenger air bag.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Page 14041
Seat Occupant Sensor: Service and Repair
Inflatable Restraint Passenger Presence System Replacement - Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Technical Service Bulletins > Page 14042
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay
> Component Information > Locations
Accessory Delay Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component
Information > Diagrams
Antenna, Navigation: Diagrams
Component Connector End Views
Cellular and Navigation Antenna (UE1)/Digital Antenna (U2K)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component
Information > Diagrams > Page 14052
Antenna, Navigation: Service and Repair
Cellular and Navigation Antenna Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Diagrams
Antenna, Phone: Diagrams
Component Connector End Views
Cellular and Navigation Antenna (UE1)/Digital Antenna (U2K)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component
Information > Diagrams > Page 14056
Antenna, Phone: Service and Repair
Cellular and Navigation Antenna Assembly Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Digital Radio Antenna Cable Replacement
Antenna Cable: Service and Repair Digital Radio Antenna Cable Replacement
Digital Radio Antenna Cable Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Digital Radio Antenna Cable Replacement > Page 14062
Antenna Cable: Service and Repair Antenna Cable Replacement
Antenna Cable Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Locations > Page 14067
Alarm Module: Diagrams
Component Connector End Views - Continued
Theft Deterrent Module (TDM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent Malfunction
Alarm Module: Testing and Inspection Content Theft Deterrent Malfunction
Content Theft Deterrent Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The content theft deterrent (CTD) system is a software based system in which the body control
module (BCM) actively monitors certain inputs to determine if unauthorized vehicle access is being
attempted. Based on inputs such as the door ajar switches, the rear compartment ajar switch, and
the hood ajar switch, the BCM determines whether a CTD alarm is warranted. If unauthorized
access is being detected, the BCM will pulse the vehicle horn and flash the turn signals as a means
of theft deterrence.
Circuit/System Verification
1. Individually open and close each vehicle door while observing the door ajar indicator/message.
The indicator/message should accurately transition
between the door ajar and door closed state when each door is opened and closed.
^ If the door ajar indicator/message does not properly transition when each door is opened and
closed, refer to Door Ajar Indicator Malfunction. See: Body and Frame/Locks/Testing and
Inspection/Symptom Related Diagnostic Procedures/Door Ajar Indicator Malfunction
2. Open and close the liftgate while observing the liftgate ajar indicator/message. The
indicator/message should accurately transition between the
liftgate ajar and liftgate closed state when the trunk is opened and closed.
^ If the liftgate ajar indicator/message does not properly transition when the liftgate is opened and
closed, refer to Liftgate Ajar Indicator Malfunction.
3. Completely lower the driver door window and close all vehicle doors. 4. Ignition OFF, arm the
CTD system using the keyless entry system by pressing the transmitter LOCK button twice. Verify
the scan tool CTD Status
parameter displays Armed.
^ If the parameter does not equal the specified value, refer to Keyless Entry System Inoperative.
See: Keyless Entry/Testing and Inspection/Symptom Related Diagnostic Procedures/Keyless Entry
System Inoperative
5. Without disarming the system, reach in through the open driver window, unlock and open the
driver door. Verify the scan tool CTD Status
parameter displays Alarm Active.
^ If the parameter does not equal the specified value, replace the BCM.
6. With the door open, verify the vehicle horn is pulsing and the exterior lamps are flashing.
^ If the horn is not pulsing, refer to Horns Malfunction. See: Lighting and Horns/Horn/Testing and
Inspection/Symptom Related Diagnostic Procedures/Horns Malfunction
^ If the exterior lights are not flashing, refer to Turn Signal Lamps and/or Indicators Malfunction.
See: Lighting and Horns/Testing and Inspection/Symptom Related Diagnostic Procedures/Turn
Signal Lamps and/or Indicators Malfunction
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft Deterrent Malfunction > Page 14070
Alarm Module: Testing and Inspection Security Indicator Malfunction
Security Indicator Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The security indicator is controlled by the Body Control Module (BCM) based on commands from
the immobilizer system or the Content Theft Deterrent (CTD) system. With the ignition OFF, the
security indicator is commanded by the CTD system. With the ignition ON, the security indicator is
commanded by the immobilizer system.
The security indicator is located in the Instrument Panel Cluster (IPC) and is supplied B+ at all
times. When the immobilizer or CTD system requests the indicator be commanded ON, the BCM
grounds the security indicator control circuit, illuminating the indicator.
Circuit/System Verification
Ignition ON, command the security indicator ON and OFF with a scan tool. The security indicator
should turn ON and OFF when changing between the commanded states.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the IPC. 2. Connect a test lamp between the
control circuit terminal 16 and B+. 3. Command the security indicator ON and OFF with a scan tool.
The test lamp should turn ON and OFF when changing between the commanded
states.
^ If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the BCM.
^ If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the BCM.
4. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module,
(Vehicle Antitheft) > Component Information > Testing and Inspection > Page 14071
Alarm Module: Service and Repair
Theft Deterrent Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch
(For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Receiver > Component Information > Diagrams
Keyless Entry Receiver: Diagrams
Component Connector End Views - Continued
Remote Control Door Lock Receiver (RCDLR)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip
Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter
Diagnostic Tip
INFORMATION
Bulletin No.: 09-08-52-004A
Date: January 08, 2010
Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter
When Transmitter Battery is Weak or Dead
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade
ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR,
Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra,
Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn
AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories).
Follow these procedures if a customer comments that their GM Accessory 2-way transmitter
stopped communicating with the vehicle.
About GM Accessory 2-Way Remote Start
The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a
2-way advanced remote start system, but often the 2-way transmitter may only be coded to one
vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter
will enter second vehicle mode and will not control the original vehicle until a subsequent double
press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of
the 2-way transmitter should be thought of as an individual transmitter with its own unique code.
Test the Transmitter Battery
Note
This test should be performed prior to releasing the vehicle or transmitter to the customer.
All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or
replacement of a transmitter battery using the following procedure.
1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of
the unlock button, observe the battery gauge located in the upper right corner of the LCD display.
The gauge should read
full (three bars inside the battery icon).
If after having a new battery installed, the battery goes dead within five months, the transmitter
could have high sleep current, causing the battery to go dead. Replace the transmitter.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition
exhibited is resolved without completing every step, the remaining steps do not need to be
performed.
Determine if Transmitter is in Second Vehicle Mode
1. Press and release any of the face buttons on the 2-way transmitter and observe the display on
power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be
displayed on the left side of the transmitter display. Is the 2-way
transmitter in second vehicle mode?
If Yes, the 2-way transmitter is working properly.
- Press and release the left side button twice within one second. The 2-way transmitter should exit
second vehicle mode.
- Press and release the lock button. Press and release the unlock button.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip > Page 14087
- Confirm that the vehicle responds with the appropriate lock and unlock function.
- If Yes , the 2-way transmitter was in mode B.
- Press and release the left side button twice within one second. The 2-way transmitter should
enter second vehicle mode.
- Use the "next available slot" method in the scan tool to program the 2-way transmitter to the
2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI.
- Both vehicle modes of the 2-way transmitter should now be coded to the vehicle.
If No:
The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal
diagnostic procedures.
Parts Information
For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts
Catalog or Corporate Bulletin Number 09-00-89-025A.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip > Page 14088
Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote
Start
INFORMATION
Bulletin No.: 09-00-89-025A
Date: October 26, 2009
Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT
2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche,
Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse
2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent
2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA,
OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY
Attention:
This bulletin does not apply to GMODC dealers.
Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin
Number 09-00-89-025 (Section 00 - General Information).
This bulletin is being published to provide information on locating service part numbers for GM
Accessory, 2-Way Advanced Remote Start Systems.
Dealers should consult the chart below and use the correct service part. Dealers should not use
entire kit for warranty or repair work.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip > Page 14089
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip > Page 14090
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless
System - Remote Start Transmitter Diagnostic Tip > Page 14091
Parts Information
Service parts common to all 2-Way Advanced Remote Start Systems
Transmitter Battery 12493150
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Transmitter Button
Inop/Won't Program
Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Transmitter Button
Inop/Won't Program
INFORMATION
Bulletin No.: 10-08-52-003
Date: July 21, 2010
Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to
Vehicle
Models:
2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007
Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade,
Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox
2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express
2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali
Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK
2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry
Attention:
This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A
copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry
(RKE) transmitter operation.
This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may
be inoperative intermittently or in which a particular button(s) does not work.
To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are
depressed longer than 30 seconds. The disabled button or buttons will remain disabled until
another button that has not been disabled is pressed.
If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed
to a vehicle, press and release each and every button on the fob one at a time until you find one
that works then retest the other buttons. If all buttons are now working, the button(s) were disabled
and the transmitter is working as designed.
If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics
as shown in SI.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 14096
Keyless Entry Transmitter: Service and Repair
Transmitter Programming
Next Available Slot
Important:
* On some vehicles, keyless entry transmitters may also be programmed using the driver
information center (DIC). Refer to the vehicle owners manual for information.
* Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless
entry program mode. This prevents the programming of the transmitters to the incorrect vehicle.
This procedure will program keyless entry transmitters in sequential order. If two transmitters are
currently learned to the vehicle as transmitters 1 and 2, using this procedure will learn the next
transmitter are transmitter 3, and so on.
1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select
Program Key Fobs. 2. Select Next Available Slot. The vehicle chime will sound two times to
indicate programming mode has been entered. Follow the on-screen
instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm
the programming.
3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF,
exit the vehicle, and operate the transmitter
functions in order to verify correct system operation.
Invalidate All Fobs
Important:
* On some vehicles, keyless entry transmitters may also be programmed using the driver
information center (DIC). Refer to the vehicle owners manual for information.
* All transmitters which are to be recognized by the remote control door lock receiver (RCDLR)
must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is
made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle
are not learned at this time, they will become inoperative and require additional programming.
* Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless
entry program mode. This prevents the programming of the transmitters to the incorrect vehicle.
This procedure will first erase all known keyless entry transmitters. After all transmitters are erased,
the procedure will being to program keyless entry transmitters in sequential order, beginning with
transmitter 1.
1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select
Program Key Fobs. 2. Select Invalidate All Fobs. This will erase all learned transmitters and
prepare the RCDLR to learn new transmitters. Follow the on-screen
instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm
the programming.
3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF,
exit the vehicle, and operate the transmitter
functions in order to verify correct system operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Diagrams
Cellular Phone Microphone: Diagrams
Component Connector End Views
Cellular Telephone Microphone (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Diagrams > Page 14101
Cellular Phone Microphone: Service and Repair
Mobile Telephone Microphone Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 14110
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 14111
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls
to OnStar(R) > Page 14112
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14118
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14119
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14120
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module:
> 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14125
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14131
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations
Central Control Module: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 3 of 3
1 - Instrument Panel Cluster (IPC) 2 - Instrument Panel Trim 3 - Vehicle Communication Interface
Module (VCIM) (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Page 14135
Central Control Module: Diagrams
Component Connector End Views - Continued
Vehicle Communication Interface Module (VCIM) X1 (UE1)
Vehicle Communication Interface Module (VCIM) X2 (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Page 14136
Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Locations > Page 14137
Vehicle Communication Interface Module (VCIM) Battery (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Service and Repair > Communication Interface Module Battery Replacement
Central Control Module: Service and Repair Communication Interface Module Battery Replacement
Communication Interface Module Battery Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Central Control Module > Component Information >
Service and Repair > Communication Interface Module Battery Replacement > Page 14140
Central Control Module: Service and Repair Communication Interface Module Replacement
Communication Interface Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
Driver/Vehicle Information Display: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14144
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14145
Driver/Vehicle Information Display: Diagrams
Component Connector End Views
Driver Information Center (DIC) Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14146
Driver/Vehicle Information Display: Description and Operation
Driver Information Center (DIC) Description and Operation
The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If
enabled through Personalization, the DIC returns to the last display status before no power
condition.
There are 7 switch functions for the DIC.
* Trip/Fuel Switch
* Vehicle Information Switch
* Personalization Switch
* Set/Reset Switch
Trip/Fuel Information Switch
The trip/fuel button is used to navigate between fuel information and trip options. Cycle through the
following trip/fuel menus by successive pressing of the trip/fuel button.
* Average Fuel Economy (AFE)
* Average Vehicle Speed (AVE)
* Elapsed Time
* Fuel Range
* Fuel Used
* Odometer
* Outside Air Temperature
* Trip Timer
* Trip A
* Trip B
* Blank
Vehicle Information Switch
The driver information center (DIC) vehicle information switch is used to navigate between various
vehicle information. Cycle through the following vehicle information by successive pressing of the
vehicle information button.
* Blank Display
* Battery Voltage
* Compass Recalibration
* Compass Zone Setting
* Engine Oil Life Index
* English/Metric Units
* Front Tire Pressure
* Key Fob Programming Menu
* Oil Pressure
* Oil Temperature
* Rear Tire Pressure
* Tire Programming Menu
Personalization Switch
The personalization switch is used to navigate between vehicle personalization options. Cycle
through the following vehicle personalization options by successive pressing of the personalization
button.
* Approach Lighting
* Auto Lock
* Auto Unlock
* Chime Volume
* Delay Lock
* Display Language
* Exit Lighting
* Factory Settings
* Feature Settings
* Remote Lock
* Remote Unlock
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14147
* Remote Start
For more information on vehicle personalization features, refer to the Owner's Manual.
Set/Reset Switch
Press the set/reset button in order to set or acknowledge any switch menu options.
Average Fuel Economy
Average fuel economy is calculated using the equation: AFE = Distance/Fuel
* Distance = The accumulated distance travelled since the last reset of this value
* Fuel = The accumulated fuel consumption since the last reset of this value
The engine control module (ECM) sends the average fuel economy serial data message to the
instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be
changed between English units and metric units by selecting from the DIC trip/fuel information
switch.
Average Vehicle Speed
Average vehicle speed is calculated using the equation: Average Speed = AVS Distance/AVS Time
* Distance = The accumulated distance travelled since the last reset of this value
* Time = The accumulated time since the last reset of this value
Fuel Range
This message indicates the estimated distance that the vehicle can travel under the current fuel
economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is
calculated using the equation: Fuel Range = Range Distance/Range Fuel Used.
* Range Distance = The accumulated distance travelled since the last reset of this value.
* Range Fuel Used = The accumulated fuel delivered since the last reset of this value
The ECM sends the fuel range value to the IPC. IPC receives a serial data message with the fuel
information. The fuel range value is retained during ignition OFF and can be changed between
English and Metric units by accessing the DIC trip/fuel information switch. The Fuel Range display
cannot be reset. LOW is displayed when fuel range is below a predetermined value.
Fuel Used
This message indicates the amount of fuel used since last reset. Fuel Used is calculated using the
equation: Fuel Used = Fuel Sum.
* Fuel Used = The accumulated fuel used since the last reset of this value.
* Fuel Sum = The accumulated fuel sum since the last reset of this value
The ECM sends the fuel used value to the IPC. The IPC receives a serial data message with the
fuel information. The fuel used value is retained as long as battery power is available to the DIC.
The fuel used value can be changed between English and Metric units by accessing the DIC
trip/fuel information switch.
Elapsed Time
The timer records elapsed time starting from activation. When the DIC displays the timer, pressing
the DIC SET/RESET switch for 1 second resets the timer. Pressing the SET/RESET button on the
DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one
of the following formats:
The DIC displays the timer in the following format: XX: XX:XX:
The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third
XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59
seconds. After the maximum range is reached, the timer displays all zeros (00:00:00).
Battery Voltage
Battery voltage data is not determined by the DIC and is not a resettable parameter. The DIC
displays (- - -) when an invalid battery data is received or when the IPC experiences a loss serial
data communications.
Engine Oil Life Index
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14148
The Engine Oil Life Index displays the estimated percentage of oil life remaining. The engine
control module (ECM) sends the oil life remaining percentage to the instrument panel cluster (IPC)
via the serial data circuit. The driver information center (DIC) displays the current percentage of the
GM Oil Life System as determined by the ECM. When the engine oil life remaining percentage
drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON message. When the engine
oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting.
Tire Pressure Monitor
The instrument panel cluster (IPC) receives serial data messages from the tire pressure monitoring
(TPM) system for the front and rear tire pressure. The driver information center (DIC) displays the
pressure for each of the front and rear tires. Tire pressure values are not reset through the DIC.
Tire Programming Menu
The DIC displays the tire programming menu. The tire programming menu is used to initiate
programming of the tire pressure monitoring sensors. The DIC displays the tire programming menu
only when the vehicle is in PARK or NEUTRAL.
Compass Zone Setting
The DIC displays the compass zone information. The DIC display allows the user to change the
currently selected compass zone. Refer to Compass Calibration and Magnetic Variance.
Compass Recalibration
The DIC provides the display that allows the resetting of the currently stored compass calibrations
data and establish new calibration data. Refer to Compass Calibration and Magnetic Variance.
Key FOB Programming Menu
The key fob programming menu is used to initiate programming of the key fobs. The key fob
programming menu can only be achieved with the vehicle transmission in PARK. Refer to
Transmitter Programming for more information on compass zone setting.
English/Metric Button
The English/Metric button is used to toggle between English and Metric unit and can be accessed
through the DIC trip/fuel switch.
Trip A/B
The trip odometer A or B can be accessed through the DIC trip/fuel switch.
Language
The driver information center (DIC) is capable of displaying in the languages listed below.
However, the DIC is capable of storing at least 3 different languages at any one time.
* English
* French
* Spanish
A simultaneous press of the DIC Vehicle Information and Personalization Switches for about 1
second provides a shortcut to change the language without understanding the currently displayed
language. The Language settings may also be assessed through the DIC personalization switch.
Outside Air Temperature
The driver information center (DIC) displays the outside air temperature based on serial data
message from the HVAC controller. The outside air temperature can be displayed in English or
Metric Units. English or Metric Units can be selected from the DIC vehicle information menu. The
DIC displays (- - -) when an invalid outside air temperature is received or communication is lost
with the HVAC controller.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14149
Oil Pressure
The driver information center (DIC) displays the engine oil pressure as determined by the ECM.
The instrument panel cluster (IPC) receives a serial data message from the ECM indicating the
current engine oil pressure.
Oil Temperature
The driver information center (DIC) displays the engine oil temperature as determined by the ECM.
The instrument panel cluster (IPC) receives a serial data message from the ECM indicating the
current engine oil temperature.
Compass
The driver information center (DIC) displays the compass based on serial data message from the
BCM. The compass module communicates with the body control module (BCM) through a
bi-directional data circuit. The instrument panel cluster (IPC) receives compass information from
the BCM via the serial data circuit. The compass is displayed in the DIC with other vehicle
information and is centered at the bottom line of the DIC. The compass display is blank when a
malfunction is present with the compass module or a compass serial data communication fault
exists. The compass displays 'CAL' or 'C' when the compass needs to be calibrated or the
compass zone needs to be reset. Cycle the ignition before performing the compass magnetic
variation adjustment procedure. The DIC vehicle information switch allows the compass zone to be
reset or the compass calibrated.
Check that the compass module is properly installed in the vehicle since this may cause the
compass to malfunction. The embossed arrow on the compass module should be parallel to the
centerline of the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 14150
Driver/Vehicle Information Display: Service and Repair
Driver Information Display Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned > Page 14159
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS
Position Reported During Call
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS
Position Reported During Call > Page 14164
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues
Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues > Page 14169
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues > Page 14170
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14176
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D
> May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004
> Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C
> Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position
Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14193
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands
Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14198
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14199
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14204
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14205
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14206
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14207
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D >
May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 >
Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C >
Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14225
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14226
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14227
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14228
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output
Jack, Entertainment System > Component Information > Diagrams
Auxiliary Input / Output Jack: Diagrams
Component Connector End Views
Audio/Video Adapter (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output
Jack, Entertainment System > Component Information > Diagrams > Page 14233
Auxiliary Input / Output Jack: Service and Repair
Auxiliary Audio/Video Input Control Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > Customer Interest for Television / Monitor: > 07-08-44-016A > Aug >
07 > Entertainment System - DVD Monitor Display Inoperative
Television / Monitor: Customer Interest Entertainment System - DVD Monitor Display Inoperative
Bulletin No.: 07-08-44-016A
Date: August 28, 2007
TECHNICAL
Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable
Connector Clamps)
Models
Supercede:
This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin
Number 07-08-44-016 (Section 08 - Body & Accessories).
Condition
Some customers may comment on an inoperative display monitor or monitors in the GM
Accessories Headrest DVD System.
Cause
This condition may be caused by a loose connection at the display monitor cable connectors.
These connectors are located at the lower rear part of both front seats. Two cables are routed to
the display monitor in each seat.
Correction
A number of headrest monitors have been replaced under warranty and in many cases, no trouble
was found by the supplier when these units were
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > Customer Interest for Television / Monitor: > 07-08-44-016A > Aug >
07 > Entertainment System - DVD Monitor Display Inoperative > Page 14242
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > Customer Interest for Television / Monitor: > 07-08-44-016A > Aug >
07 > Entertainment System - DVD Monitor Display Inoperative > Page 14243
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Television / Monitor: >
07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative
Television / Monitor: All Technical Service Bulletins Entertainment System - DVD Monitor Display
Inoperative
Bulletin No.: 07-08-44-016A
Date: August 28, 2007
TECHNICAL
Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable
Connector Clamps)
Models
Supercede:
This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin
Number 07-08-44-016 (Section 08 - Body & Accessories).
Condition
Some customers may comment on an inoperative display monitor or monitors in the GM
Accessories Headrest DVD System.
Cause
This condition may be caused by a loose connection at the display monitor cable connectors.
These connectors are located at the lower rear part of both front seats. Two cables are routed to
the display monitor in each seat.
Correction
A number of headrest monitors have been replaced under warranty and in many cases, no trouble
was found by the supplier when these units were
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Television / Monitor: >
07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 14249
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Television / Monitor: >
07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 14250
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > Page 14251
Television / Monitor: Diagrams
Component Connector End Views - Continued
Video Display (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor >
Component Information > Technical Service Bulletins > Page 14252
Television / Monitor: Service and Repair
Video Display Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest for DVD Player: > 06-08-44-032B > Apr > 08 > Entertainment
System - Rear DVD Screen Inoperative/Blank
DVD Player: Customer Interest Entertainment System - Rear DVD Screen Inoperative/Blank
TECHNICAL
Bulletin No.: 06-08-44-032B
Date: April 10, 2008
Subject: Rear (2nd and *3rd Row (*where applicable)) DVD Screen Blank/Inoperative, Speaker
Pop Noise, Battery Draw, OnStar(R) Audio Inoperative, Nav Screen Flashing, Radio Display
Flashing (Inspect and Repair Wiring Harness if Necessary)
Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT* 2007 Chevrolet Avalanche,
Silverado, Suburban, Tahoe* 2007-2008 Chevrolet Equinox 2007 GMC Sierra, Yukon, Yukon XL,
Yukon Denali, Yukon Denali XL* 2007-2008 Pontiac Torrent
with Rear Seat Entertainment System (RPOs U42, UUC)
Supercede:
This bulletin is being revised to add RPO UUC. Please discard Corporate Bulletin Number
06-08-44-032A (Section 08 - Body and Accessories).
Condition
Some customers may comment on any one of the following concerns:
^ Rear DVD Screen Inoperative.
^ Pop Noise in all speakers when cranking the engine.
^ Battery Draw or Battery goes dead.
^ OnStar(R) Inoperative.
^ No Sound from speakers.
^ No OnStar(R) Audio.
^ Navigation screen "Flashing on and off".
^ Radio display "Flashing on and off".
Cause
This condition may be due to an open or shorted wiring harness near the rear DVD display screen
under the headliner.
Correction
To properly inspect for this condition perform the following steps:
1. Lower the rear DVD screen.
2. Remove the four retaining screws that hold the DVD to the headliner. In order to remove the
screen assembly from the overhead bezel a firm tug should be applied to unseat the Z-axis clip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest for DVD Player: > 06-08-44-032B > Apr > 08 > Entertainment
System - Rear DVD Screen Inoperative/Blank > Page 14261
3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole.
Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing).
4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for
diagnosis and repair of the system.
5. Install the DVD screen and the four retaining screws.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment
System - DVD Monitor Display Inoperative
DVD Player: Customer Interest Entertainment System - DVD Monitor Display Inoperative
Bulletin No.: 07-08-44-016A
Date: August 28, 2007
TECHNICAL
Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable
Connector Clamps)
Models
Supercede:
This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin
Number 07-08-44-016 (Section 08 - Body & Accessories).
Condition
Some customers may comment on an inoperative display monitor or monitors in the GM
Accessories Headrest DVD System.
Cause
This condition may be caused by a loose connection at the display monitor cable connectors.
These connectors are located at the lower rear part of both front seats. Two cables are routed to
the display monitor in each seat.
Correction
A number of headrest monitors have been replaced under warranty and in many cases, no trouble
was found by the supplier when these units were
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment
System - DVD Monitor Display Inoperative > Page 14266
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment
System - DVD Monitor Display Inoperative > Page 14267
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 06-08-44-032B > Apr > 08 >
Entertainment System - Rear DVD Screen Inoperative/Blank
DVD Player: All Technical Service Bulletins Entertainment System - Rear DVD Screen
Inoperative/Blank
TECHNICAL
Bulletin No.: 06-08-44-032B
Date: April 10, 2008
Subject: Rear (2nd and *3rd Row (*where applicable)) DVD Screen Blank/Inoperative, Speaker
Pop Noise, Battery Draw, OnStar(R) Audio Inoperative, Nav Screen Flashing, Radio Display
Flashing (Inspect and Repair Wiring Harness if Necessary)
Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT* 2007 Chevrolet Avalanche,
Silverado, Suburban, Tahoe* 2007-2008 Chevrolet Equinox 2007 GMC Sierra, Yukon, Yukon XL,
Yukon Denali, Yukon Denali XL* 2007-2008 Pontiac Torrent
with Rear Seat Entertainment System (RPOs U42, UUC)
Supercede:
This bulletin is being revised to add RPO UUC. Please discard Corporate Bulletin Number
06-08-44-032A (Section 08 - Body and Accessories).
Condition
Some customers may comment on any one of the following concerns:
^ Rear DVD Screen Inoperative.
^ Pop Noise in all speakers when cranking the engine.
^ Battery Draw or Battery goes dead.
^ OnStar(R) Inoperative.
^ No Sound from speakers.
^ No OnStar(R) Audio.
^ Navigation screen "Flashing on and off".
^ Radio display "Flashing on and off".
Cause
This condition may be due to an open or shorted wiring harness near the rear DVD display screen
under the headliner.
Correction
To properly inspect for this condition perform the following steps:
1. Lower the rear DVD screen.
2. Remove the four retaining screws that hold the DVD to the headliner. In order to remove the
screen assembly from the overhead bezel a firm tug should be applied to unseat the Z-axis clip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 06-08-44-032B > Apr > 08 >
Entertainment System - Rear DVD Screen Inoperative/Blank > Page 14273
3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole.
Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing).
4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for
diagnosis and repair of the system.
5. Install the DVD screen and the four retaining screws.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 >
Entertainment System - DVD Monitor Display Inoperative
DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display
Inoperative
Bulletin No.: 07-08-44-016A
Date: August 28, 2007
TECHNICAL
Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable
Connector Clamps)
Models
Supercede:
This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin
Number 07-08-44-016 (Section 08 - Body & Accessories).
Condition
Some customers may comment on an inoperative display monitor or monitors in the GM
Accessories Headrest DVD System.
Cause
This condition may be caused by a loose connection at the display monitor cable connectors.
These connectors are located at the lower rear part of both front seats. Two cables are routed to
the display monitor in each seat.
Correction
A number of headrest monitors have been replaced under warranty and in many cases, no trouble
was found by the supplier when these units were
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 >
Entertainment System - DVD Monitor Display Inoperative > Page 14278
analyzed. Therefore, technicians should be checking for loose connections and installing cable
connector clamps to ensure a positive and robust connection.
Technicians are to install a video cable connector clamp on each cable connector located under
each front seat. A total of four cable connector clamps, P/N 19159659, are required for each
vehicle.
The illustration above shows a pair of display monitor cable connectors without the cable clamps
installed.
The illustration above shows the display monitor cable connectors with the cable connector clamps.
The lower cable connector clamp is installed but not locked together. The upper cable connector
clamp is closed and locked.
The cable connector clamps have now been added as a permanent component to all GM
Accessories Headrest DVD Systems installation kits.
Parts Information
Warranty Information (excluding Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 >
Entertainment System - DVD Monitor Display Inoperative > Page 14279
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System
Control Module > Component Information > Diagrams
Entertainment System Control Module: Diagrams
Component Connector End Views - Continued
Infrared Transmitter Module (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones
> Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement
Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam
Pad Replacement
Bulletin No.: 05-08-44-005A
Date: July 19, 2007
INFORMATION
Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2, H3 2005-2008 Saab 9-7X
with Rear Seat Entertainment System (RPOs U32, U42)
Supercede:
This bulletin is being revised to add models and model years and update the shipping costs.
Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories).
Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear
pads may wear out when not handled and stored carefully.
If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced
separately from the headphone set. It is not necessary to replace the complete headphone set.
Parts Information
All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice.
The headphone replacement foam ear pads can be ordered in pairs directly through the supplier.
Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N
CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned
Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number
Incorrect/Incorrectly Assigned > Page 14295
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS
Position Reported During Call
Global Positioning System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During
Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS
Position Reported During Call > Page 14300
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues
Global Positioning System: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues > Page 14305
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS
Signal/Hands Free Issues > Page 14306
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly
Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C
> Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14312
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B
> Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing
Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B
> Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14317
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-44-007D
> May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Global Positioning System: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 08-08-46-004 >
Aug > 08 > OnStar(R) - Aftermarket Device Interference Information
Global Positioning System: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 00-08-46-004C
> Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Global Positioning System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Global Positioning System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position
Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-46-006C
> Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14334
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Global Positioning System: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands
Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
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Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14339
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 02-08-46-007C
> Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14340
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information
Global Positioning System: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14345
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14346
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14347
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-009B
> Jun > 07 > OnStar(R) - Language Change Information > Page 14348
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B >
Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing
Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B >
Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14354
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 02-08-44-007D >
May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Global Positioning System: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 08-08-46-004 > Aug
> 08 > OnStar(R) - Aftermarket Device Interference Information
Global Positioning System: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 00-08-46-004C >
Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications
Global Positioning System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information
Global Positioning System: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14371
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14372
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14373
Method 1
Method 2
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 05-08-46-009B >
Jun > 07 > OnStar(R) - Language Change Information > Page 14374
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page
14383
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page
14384
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page
14385
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly
Assigned
Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly
Assigned > Page 14391
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-44-013E > Jul > 09 > Navigation Radio - Intermittent Blank/Black
Screen
Technical Service Bulletin # 08-08-44-013E Date: 090727
Navigation Radio - Intermittent Blank/Black Screen
TECHNICAL
Bulletin No.: 08-08-44-013E
Date: July 27, 2009
Subject: Navigation Radio Intermittent Blank/Black Screen, Map Disc Read Errors, Features Not
Accessible While Driving, Navigation Radio Resets Upon Startup (Update Navigation Radio
Software)
Models:
2006-2008 Buick Lucerne 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008
Chevrolet Equinox 2007-2008 GMC Acadia 2007-2008 Pontiac Torrent 2007-2008 Saturn
OUTLOOK, VUE All Equipped with Navigation Radio (RPOs U3R, UZR, U3U, UVB)
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada only.
Supercede: This bulletin is being revised to remove the NAV Disc Center Website information.
Please discard Corporate Bulletin Number 08-08-44-013D (Section 08 - Body and Accessories).
Note
If the vehicle has a 2008 MY radio and the software version is 100M or higher (e.g. 100N) for the
SuperNav navigation system (Escalades) or 100F or higher (e.g. 100G) for the BlackTie navigation
systems (Lucerne, Enclave, Equinox, Acadia, Torrent, Outlook, and VUE), the
improvements/corrections offered via update disc 20774148 are already installed and this update is
not required. The screen will display the following message "The disc installed is not a MAP DVD".
THIS IS NOT AN ERROR MESSAGE.
Condition
Customers may comment on any of the following conditions:
- The Navigation Radio display intermittently goes blank or turns black/off after switching video
sources. This most commonly occurs when the shift lever is transitioned from PARK to REVERSE
to DRIVE (or vice versa). Other possibilities include switching to DVD movie or Rear AUX (if
equipped).
- The Navigation Radio screen may intermittently freeze, lock up or display "MAP DVD Read Error"
messages.
- Some features may not be accessible while driving. This includes scrolling lists, address book and
navigation related entries (i.e. entering a destination).
- The Navigation Radio, upon startup, will continue to display the vehicle logo repeatedly. This
condition occurs when the vehicle language has been changed, using the Driver Information
Center (DIC), in the previous ignition cycle.
Cause
These conditions may be caused by software anomalies.
Parts Information (S/W included on disc)
Navigation software update discs are for the dealer to update the Navigation Radio software only.
They DO NOT update or replace the navigation map
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-44-013E > Jul > 09 > Navigation Radio - Intermittent Blank/Black
Screen > Page 14396
disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited
supply of these discs available. Do not order these discs for stock. Do not give the software update
disc to the customer. Navigation software discs may be used to reprogram more than one vehicle.
The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer
will cost $50 (USD). Refer to Corporate Bulletin Number 06-08-44-012C for additional information
on how to obtain AVN software update discs.
GM Navigation Disc Center Contact Information
Note
Navigation Radio Software Update Discs are no longer available via the Web.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Correction
Correction
Technicians are to update the Navigation Radio software using a software update disc, P/N
20774148. The software update disc is to be obtained from the GM Navigation Disc Center, using
the contact information below. Follow one of the two procedures below as appropriate for the
vehicle you are working on.
Navigation Radio Software Update For Cadillac Escalade Models 2007-2008
Note If the radio has software calibration 100M (2008 MY radios or earlier) or higher (e.g. 100N,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD". THIS IS NOT AN ERROR MESSAGE. To verify the software version follow steps 1
and 2 below.
Important For the condition regarding features not accessible while driving, this will only be
addressed in 2007 and 2008 model year Cadillac Escalade vehicles.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-44-013E > Jul > 09 > Navigation Radio - Intermittent Blank/Black
Screen > Page 14397
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the CONFIG and SEEK UP buttons (1)
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above which shows the two buttons that need to be pressed. The navigation
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100M (2008 MY or earlier) or higher, the radio has the latest
navigation software available and no update is
necessary. However, if the string of letters across the screen are NON-ASCII letters, this indicates
an internal communication problem with the RADIO. Refer to the Diagnostic Starting Point-Cellular,
Entertainment, and Navigation procedure to begin the diagnosis of the customer concern. For all
other navigation software versions proceed to step four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Eject the map disc from the top map DVD slot, callout (2) in the illustration above, if present.
Load the software update disc, P/N 20774148, into
the top map DVD slot.
5. The display will show "Update in Progress" and upon successful software upgrade, the screen
will transition to a blue screen with "The disc
installed is not a MAP DVD" displayed on the screen. It will take approximately five minutes to load
the new software. Eject the software update disc from the top map DVD slot and retain at your
dealership.
6. Confirm that the new navigation software version is 100M using the procedure in step two
above. 7. Install the customer's original map disc, if it was present. If the customer concern was
related to limitations while driving, confirm that the "Limit
Features While Driving" feature is turned off by pressing the CONFIG button followed by the Radio
tab and "Limit Features While Driving" tab. "Limit Features While Driving" should be unselected to
match the customer's preference.
8. Verify proper operation of the Navigation Radio.
Navigation Radio Software Update For All Other Vehicles (2007-2008 Chevrolet Equinox, Pontiac
Torrent; 2007-2008 GMC Acadia, Saturn OUTLOOK, Saturn VUE 2008 Buick Enclave and
2006-2008 Buick Lucerne)
Note If the radio has software calibration 100F (2008 MY radios or earlier) or higher (e.g. 100G,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD" THIS IS NOT AN ERROR MESSAGE. To verify the software version follow step 1 and
2 below.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the MENU and SEEK UP (1) buttons
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above, which shows the two buttons that need to be pressed. The
navigation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-44-013E > Jul > 09 > Navigation Radio - Intermittent Blank/Black
Screen > Page 14398
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100F (2008 MY radios or earlier) or higher, the software
corrections contained on the update disc 20774148
are already installed and this update is not required. However, if the string of letters across the
screen are NON-ASCII letters, this indicates an internal communication problem with the RADIO.
Refer to the Diagnostic Starting Point-Cellular, Entertainment, and Navigation procedure to begin
the diagnosis of the customer concern. For all other navigation software versions proceed to step
four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Open the front display by pressing and holding the EJECT (1) button for approximately 15
seconds. Eject the map disc from the revealed map
DVD slot by pressing the EJECT (2) button located beneath the revealed map DVD slot. Load the
software update disc, P/N 20774148, in map drive (3).
5. Close the front display by using both hands at the four corners of the display until the display fits
securely into the radio. Do not push on the touch
screen to close. The display will show "Update in Progress" and upon successful software update,
the screen will transition to a blue screen with "The disc installed is not a MAP DVD" displayed on
the screen. It will take approximately five minutes to load the new software.
6. Confirm that the new navigation software version is either 101B or 100F using the procedure in
step two above. 7. Verify proper operation of the Navigation Radio.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position
Reported During Call
Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position
Reported During Call > Page 14403
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 07-08-44-026 > Nov > 07 > Navigation System - Obsolete Data/Voice
Commands Inop.
Navigation System: Customer Interest Navigation System - Obsolete Data/Voice Commands Inop.
Bulletin No.: 07-08-44-026
Date: November 01, 2007
TECHNICAL
Subject: Navigation System Has Old Map Data And/Or Voice Recognition Commands Do Not Work
(Install 2008 Model Year Map Disc)
Models: 2008 Buick Lucerne 2008 Chevrolet Equinox 2008 GMC Acadia 2008 Pontiac Torrent
2008 Saturn OUTLOOK, VUE
with Navigation Radio (RPO U3U Equinox, Lucerne, Torrent, VUE) (RPO U3R or UZR Acadia,
Enclave, OUTLOOK)
Attention:
This condition affects a limited number of 2008 model year vehicles with a navigation radio that is
being used with a 2007 model year map disc, P/N 10396714.
Condition
Some customers may comment on the following conditions:
The navigation radio may display map data that is obsolete.
The navigation radio voice recognition commands do not work. These system commands are:
System Help
Display Day Mode
Display Night Mode
Display Auto Mode
This condition is NOT to be confused with the condition of the OnStar(R) voice recognition
commands not working. That is a different condition and is corrected by activating OnStar(R)
personal calling, NOT by using a 2008 model year map disc.
Correction
Technicians are not to replace the navigation radio for any of the conditions listed above. Use the
following procedure to correct these conditions:
Refer to the VIN of the vehicle to verify that it is a 2008 model. The tenth character of the VIN must
be an 8.
If the vehicle is a 2008 model, verify that the map disc loaded in the radio is actually a 2007 model
year disc, part number 10396714.
If the vehicle is a 2008 model and has a 2007 model year map disc, contact the Navigation (NAV)
Disc Center and request a new 2008 model year map disc, P/N 25880099.
Install the new map disc into the navigation radio and verify proper operation of the navigation
system. The conditions listed above will be corrected automatically the first time the new map disc
is inserted into the radio. No setup procedure is required.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Customer Interest: > 07-08-44-026 > Nov > 07 > Navigation System - Obsolete Data/Voice
Commands Inop. > Page 14408
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 >
OnStar(R) - Number Incorrect/Incorrectly Assigned
Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly
Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 >
OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14414
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation
- Report Missing/Inaccurate Nav. Map Info
Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav.
Map Info
INFORMATION
Bulletin No.: 10-08-44-006
Date: October 11, 2010
Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and
Submit Feedback Form at GM Navigation Disc Center Website
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio
Some customers may notice that some navigation radio map discs may have missing or incorrect
information.
The following list contains some examples:
- Missing or incorrect roads, road names or road shapes
- Missing or incorrect addresses
- Missing or incorrect highway labeling
- Missing or incorrect highway exit numbers
- Missing or incorrect traffic restrictions
- Missing points of interest (POI) or incorrect details, such as location, category or phone number
General Motors uses a map database from two different suppliers. The two map suppliers are
consistently updating their map database and will gladly accept any input regarding missing or
incorrect information on the navigation radio map disc.
To report any missing or incorrect information, please access the GM Navigation Disc Center at the
following web site: http://www.gmnavdisc.com.
At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation
Data Feedback form, fill in the appropriate information as required and then select: Submit, to send
the form.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 >
Navigation System - Software/DVD Update Program
Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update
Program
INFORMATION
Bulletin No.: 06-08-44-012E
Date: April 20, 2010
Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update
Discs and Ordering Information
Models:
2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3
2005-2009 Saab 9-7X
Attention:
Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and
Used Car Department. This bulletin ONLY applies to North American dealers/retailers.
Supercede: This bulletin is being revised to include the 2010 model year and update the usage
table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and
Accessories).
DVD Navigation Update Program
The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the
functionality of the navigation system declines. Offering GM customers new navigation DVDs will
ensure that the customers have the latest information for their system.
General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles.
This program concluded on December 31, 2009. The DVD Navigation Update Program policy has
changed and customers are no longer eligible for free annual updates, however, a navigation DVD
update disc can be purchased for $199 (USD) + shipping.
If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD).
The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the
GM Navigation Disc Center, as this option is not available on the website.
The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an
updated disc:
- Via the web through gmnavdisc.com
- GM Navigation Disc Center
Navigation Disc Diagnostic Aid
The following table can be used to identify acceptable discs for testing the navigation unit's map
drive functionality. This should only be used to verify the map drive's ability to read the map disc
properly and to determine if there is an issue with the unit's map drive or the disc. Some functions,
such as voice recognition, may not work properly with some of the discs in the list. If the disc is
found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc
for the vehicle.
AVN Software Update Discs
Technical Service Bulletins are sometimes generated to address specific navigation radio
operational or performance issues. When a navigation radio bulletin is issued, it may contain
instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part
number. GM dealers must order advanced vehicle navigation (AVN) software update discs as
directed in the specific bulletin.
AVN software update discs are for the dealer to update the navigation radio software only. They do
NOT update or replace the navigation map disc that is supplied with the vehicle. Please order
these parts only as needed. There is a limited supply of these discs available. Do not order these
discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The
first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will
cost $50 (USD).
To obtain an AVN software update disc, follow the specific ordering information provided in the
bulletin.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 >
Navigation System - Software/DVD Update Program > Page 14423
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14428
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14429
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14430
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 >
OnStar(R) - Availability for Hearing Impaired
Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 >
OnStar(R) - Availability for Hearing Impaired > Page 14435
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 >
Navigation Radio - Intermittent Blank/Black Screen
Technical Service Bulletin # 08-08-44-013E Date: 090727
Navigation Radio - Intermittent Blank/Black Screen
TECHNICAL
Bulletin No.: 08-08-44-013E
Date: July 27, 2009
Subject: Navigation Radio Intermittent Blank/Black Screen, Map Disc Read Errors, Features Not
Accessible While Driving, Navigation Radio Resets Upon Startup (Update Navigation Radio
Software)
Models:
2006-2008 Buick Lucerne 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008
Chevrolet Equinox 2007-2008 GMC Acadia 2007-2008 Pontiac Torrent 2007-2008 Saturn
OUTLOOK, VUE All Equipped with Navigation Radio (RPOs U3R, UZR, U3U, UVB)
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada only.
Supercede: This bulletin is being revised to remove the NAV Disc Center Website information.
Please discard Corporate Bulletin Number 08-08-44-013D (Section 08 - Body and Accessories).
Note
If the vehicle has a 2008 MY radio and the software version is 100M or higher (e.g. 100N) for the
SuperNav navigation system (Escalades) or 100F or higher (e.g. 100G) for the BlackTie navigation
systems (Lucerne, Enclave, Equinox, Acadia, Torrent, Outlook, and VUE), the
improvements/corrections offered via update disc 20774148 are already installed and this update is
not required. The screen will display the following message "The disc installed is not a MAP DVD".
THIS IS NOT AN ERROR MESSAGE.
Condition
Customers may comment on any of the following conditions:
- The Navigation Radio display intermittently goes blank or turns black/off after switching video
sources. This most commonly occurs when the shift lever is transitioned from PARK to REVERSE
to DRIVE (or vice versa). Other possibilities include switching to DVD movie or Rear AUX (if
equipped).
- The Navigation Radio screen may intermittently freeze, lock up or display "MAP DVD Read Error"
messages.
- Some features may not be accessible while driving. This includes scrolling lists, address book and
navigation related entries (i.e. entering a destination).
- The Navigation Radio, upon startup, will continue to display the vehicle logo repeatedly. This
condition occurs when the vehicle language has been changed, using the Driver Information
Center (DIC), in the previous ignition cycle.
Cause
These conditions may be caused by software anomalies.
Parts Information (S/W included on disc)
Navigation software update discs are for the dealer to update the Navigation Radio software only.
They DO NOT update or replace the navigation map
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 >
Navigation Radio - Intermittent Blank/Black Screen > Page 14440
disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited
supply of these discs available. Do not order these discs for stock. Do not give the software update
disc to the customer. Navigation software discs may be used to reprogram more than one vehicle.
The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer
will cost $50 (USD). Refer to Corporate Bulletin Number 06-08-44-012C for additional information
on how to obtain AVN software update discs.
GM Navigation Disc Center Contact Information
Note
Navigation Radio Software Update Discs are no longer available via the Web.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Correction
Correction
Technicians are to update the Navigation Radio software using a software update disc, P/N
20774148. The software update disc is to be obtained from the GM Navigation Disc Center, using
the contact information below. Follow one of the two procedures below as appropriate for the
vehicle you are working on.
Navigation Radio Software Update For Cadillac Escalade Models 2007-2008
Note If the radio has software calibration 100M (2008 MY radios or earlier) or higher (e.g. 100N,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD". THIS IS NOT AN ERROR MESSAGE. To verify the software version follow steps 1
and 2 below.
Important For the condition regarding features not accessible while driving, this will only be
addressed in 2007 and 2008 model year Cadillac Escalade vehicles.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 >
Navigation Radio - Intermittent Blank/Black Screen > Page 14441
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the CONFIG and SEEK UP buttons (1)
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above which shows the two buttons that need to be pressed. The navigation
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100M (2008 MY or earlier) or higher, the radio has the latest
navigation software available and no update is
necessary. However, if the string of letters across the screen are NON-ASCII letters, this indicates
an internal communication problem with the RADIO. Refer to the Diagnostic Starting Point-Cellular,
Entertainment, and Navigation procedure to begin the diagnosis of the customer concern. For all
other navigation software versions proceed to step four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Eject the map disc from the top map DVD slot, callout (2) in the illustration above, if present.
Load the software update disc, P/N 20774148, into
the top map DVD slot.
5. The display will show "Update in Progress" and upon successful software upgrade, the screen
will transition to a blue screen with "The disc
installed is not a MAP DVD" displayed on the screen. It will take approximately five minutes to load
the new software. Eject the software update disc from the top map DVD slot and retain at your
dealership.
6. Confirm that the new navigation software version is 100M using the procedure in step two
above. 7. Install the customer's original map disc, if it was present. If the customer concern was
related to limitations while driving, confirm that the "Limit
Features While Driving" feature is turned off by pressing the CONFIG button followed by the Radio
tab and "Limit Features While Driving" tab. "Limit Features While Driving" should be unselected to
match the customer's preference.
8. Verify proper operation of the Navigation Radio.
Navigation Radio Software Update For All Other Vehicles (2007-2008 Chevrolet Equinox, Pontiac
Torrent; 2007-2008 GMC Acadia, Saturn OUTLOOK, Saturn VUE 2008 Buick Enclave and
2006-2008 Buick Lucerne)
Note If the radio has software calibration 100F (2008 MY radios or earlier) or higher (e.g. 100G,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD" THIS IS NOT AN ERROR MESSAGE. To verify the software version follow step 1 and
2 below.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the MENU and SEEK UP (1) buttons
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above, which shows the two buttons that need to be pressed. The
navigation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 >
Navigation Radio - Intermittent Blank/Black Screen > Page 14442
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100F (2008 MY radios or earlier) or higher, the software
corrections contained on the update disc 20774148
are already installed and this update is not required. However, if the string of letters across the
screen are NON-ASCII letters, this indicates an internal communication problem with the RADIO.
Refer to the Diagnostic Starting Point-Cellular, Entertainment, and Navigation procedure to begin
the diagnosis of the customer concern. For all other navigation software versions proceed to step
four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Open the front display by pressing and holding the EJECT (1) button for approximately 15
seconds. Eject the map disc from the revealed map
DVD slot by pressing the EJECT (2) button located beneath the revealed map DVD slot. Load the
software update disc, P/N 20774148, in map drive (3).
5. Close the front display by using both hands at the four corners of the display until the display fits
securely into the radio. Do not push on the touch
screen to close. The display will show "Update in Progress" and upon successful software update,
the screen will transition to a blue screen with "The disc installed is not a MAP DVD" displayed on
the screen. It will take approximately five minutes to load the new software.
6. Confirm that the new navigation software version is either 101B or 100F using the procedure in
step two above. 7. Verify proper operation of the Navigation Radio.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 >
OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl
Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips
Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips
INFORMATION
Bulletin No.: 08-08-44-010F
Date: March 09, 2009
Subject: Navigation Radio Diagnostic Tips
Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior
HUMMER H2, H3 2008 and Prior Saab 9-7X
All Equipped with Navigation Radio
Supercede:
This bulletin is being revised to update the model years involved, the radio part number list, remove
the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin
Number 08-08-44-010E (Section 08 - Body and Accessories).
Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test
as defective. In many cases, published SI documents were available to correct the condition
without the need for an exchange unit. The following Diagnostic Tips may assist with the proper
diagnosis and repair of Navigation Radio Concerns.
Note
For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction
through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and
Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow
the normal process and contact an authorized Electronic Service Center (ESC) for assistance.
For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the
returned radio. Be sure to document the customer's concern in detail, including unusual noises and
what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO.
Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly.
Note
Navigation Radios with physical damage (for example: shattered displays, impact damage to the
radio face and fluid damage) must be reviewed with the District Service Manager for appropriate
coverage prior to replacing the radio. The dealership must note the District Service Manager's
approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT
disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the
dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate
Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters.
Getting Started
Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin
Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD)
Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate
Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find
the corresponding Diagnostic Tips Review.
Printing This Document
To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the
arrows at the top of the screen to scroll left and right through the bulletin to identify the correct
pages containing the questions. With the pages identified, click on the Print button at the top left. In
the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print
pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in,
click the Print box at the bottom of the pop-up box.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14451
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14452
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14453
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14454
Diagnostic Tips Review Table
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14455
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14456
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14457
Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14458
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14459
Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14460
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14461
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14462
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14463
Diagnostic Tips Review # 3 - Denso Navigation Radios
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14464
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14465
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14466
Diagnostic Tips Review # 4 - Denso legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14467
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 >
Navigation Radio - Diagnostic Tips > Page 14468
Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R)
- Aftermarket Device Interference Information
Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference
Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation
Radio - Adaptation After Radio/Battery R&R;
Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After
Radio/Battery R&R;
INFORMATION
Bulletin No.: 08-08-44-023
Date: June 18, 2008
Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio
Replacement, Power Loss Or Battery Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
with Navigation Radio
The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may
not display the vehicle location icon on the map accurately after a radio or battery has been
replaced or after battery power has been removed from the radio. The vehicle location icon
accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red
line through it.
The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed
signals stored when the battery power is removed from the radio. The Navigation radio continually
uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned
accurately on the displayed map. There may be periods of time during a drive cycle when the GPS
signal may not be available and the vehicle location icon still appears to be accurate. This is due to
the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if
the radio had received a good GPS signal earlier in the drive cycle.
Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may
be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while
the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this
condition.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 >
OnStar(R) - Re-establishing OnStar(R) Communications
Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 >
OnStar(R) - Incorrect GPS Position Reported During Call
Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 >
OnStar(R) - Incorrect GPS Position Reported During Call > Page 14485
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-026 > Nov > 07 >
Navigation System - Obsolete Data/Voice Commands Inop.
Navigation System: All Technical Service Bulletins Navigation System - Obsolete Data/Voice
Commands Inop.
Bulletin No.: 07-08-44-026
Date: November 01, 2007
TECHNICAL
Subject: Navigation System Has Old Map Data And/Or Voice Recognition Commands Do Not Work
(Install 2008 Model Year Map Disc)
Models: 2008 Buick Lucerne 2008 Chevrolet Equinox 2008 GMC Acadia 2008 Pontiac Torrent
2008 Saturn OUTLOOK, VUE
with Navigation Radio (RPO U3U Equinox, Lucerne, Torrent, VUE) (RPO U3R or UZR Acadia,
Enclave, OUTLOOK)
Attention:
This condition affects a limited number of 2008 model year vehicles with a navigation radio that is
being used with a 2007 model year map disc, P/N 10396714.
Condition
Some customers may comment on the following conditions:
The navigation radio may display map data that is obsolete.
The navigation radio voice recognition commands do not work. These system commands are:
System Help
Display Day Mode
Display Night Mode
Display Auto Mode
This condition is NOT to be confused with the condition of the OnStar(R) voice recognition
commands not working. That is a different condition and is corrected by activating OnStar(R)
personal calling, NOT by using a 2008 model year map disc.
Correction
Technicians are not to replace the navigation radio for any of the conditions listed above. Use the
following procedure to correct these conditions:
Refer to the VIN of the vehicle to verify that it is a 2008 model. The tenth character of the VIN must
be an 8.
If the vehicle is a 2008 model, verify that the map disc loaded in the radio is actually a 2007 model
year disc, part number 10396714.
If the vehicle is a 2008 model and has a 2007 model year map disc, contact the Navigation (NAV)
Disc Center and request a new 2008 model year map disc, P/N 25880099.
Install the new map disc into the navigation radio and verify proper operation of the navigation
system. The conditions listed above will be corrected automatically the first time the new map disc
is inserted into the radio. No setup procedure is required.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-026 > Nov > 07 >
Navigation System - Obsolete Data/Voice Commands Inop. > Page 14490
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 >
OnStar(R) - Language Change Information
Navigation System: All Technical Service Bulletins OnStar(R) - Language Change Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 >
OnStar(R) - Language Change Information > Page 14495
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 >
OnStar(R) - Language Change Information > Page 14496
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 >
OnStar(R) - Language Change Information > Page 14497
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 >
OnStar(R) - Language Change Information > Page 14498
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned
Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly
Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 14504
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info
Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav.
Map Info
INFORMATION
Bulletin No.: 10-08-44-006
Date: October 11, 2010
Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and
Submit Feedback Form at GM Navigation Disc Center Website
Models:
2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio
Some customers may notice that some navigation radio map discs may have missing or incorrect
information.
The following list contains some examples:
- Missing or incorrect roads, road names or road shapes
- Missing or incorrect addresses
- Missing or incorrect highway labeling
- Missing or incorrect highway exit numbers
- Missing or incorrect traffic restrictions
- Missing points of interest (POI) or incorrect details, such as location, category or phone number
General Motors uses a map database from two different suppliers. The two map suppliers are
consistently updating their map database and will gladly accept any input regarding missing or
incorrect information on the navigation radio map disc.
To report any missing or incorrect information, please access the GM Navigation Disc Center at the
following web site: http://www.gmnavdisc.com.
At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation
Data Feedback form, fill in the appropriate information as required and then select: Submit, to send
the form.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation
System - Software/DVD Update Program
Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update
Program
INFORMATION
Bulletin No.: 06-08-44-012E
Date: April 20, 2010
Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update
Discs and Ordering Information
Models:
2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3
2005-2009 Saab 9-7X
Attention:
Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and
Used Car Department. This bulletin ONLY applies to North American dealers/retailers.
Supercede: This bulletin is being revised to include the 2010 model year and update the usage
table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and
Accessories).
DVD Navigation Update Program
The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the
functionality of the navigation system declines. Offering GM customers new navigation DVDs will
ensure that the customers have the latest information for their system.
General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles.
This program concluded on December 31, 2009. The DVD Navigation Update Program policy has
changed and customers are no longer eligible for free annual updates, however, a navigation DVD
update disc can be purchased for $199 (USD) + shipping.
If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD).
The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the
GM Navigation Disc Center, as this option is not available on the website.
The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an
updated disc:
- Via the web through gmnavdisc.com
- GM Navigation Disc Center
Navigation Disc Diagnostic Aid
The following table can be used to identify acceptable discs for testing the navigation unit's map
drive functionality. This should only be used to verify the map drive's ability to read the map disc
properly and to determine if there is an issue with the unit's map drive or the disc. Some functions,
such as voice recognition, may not work properly with some of the discs in the list. If the disc is
found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc
for the vehicle.
AVN Software Update Discs
Technical Service Bulletins are sometimes generated to address specific navigation radio
operational or performance issues. When a navigation radio bulletin is issued, it may contain
instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part
number. GM dealers must order advanced vehicle navigation (AVN) software update discs as
directed in the specific bulletin.
AVN software update discs are for the dealer to update the navigation radio software only. They do
NOT update or replace the navigation map disc that is supplied with the vehicle. Please order
these parts only as needed. There is a limited supply of these discs available. Do not order these
discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The
first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will
cost $50 (USD).
To obtain an AVN software update disc, follow the specific ordering information provided in the
bulletin.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation
System - Software/DVD Update Program > Page 14513
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) Availability for Hearing Impaired
Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) Availability for Hearing Impaired > Page 14518
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 > Navigation
Radio - Intermittent Blank/Black Screen
Technical Service Bulletin # 08-08-44-013E Date: 090727
Navigation Radio - Intermittent Blank/Black Screen
TECHNICAL
Bulletin No.: 08-08-44-013E
Date: July 27, 2009
Subject: Navigation Radio Intermittent Blank/Black Screen, Map Disc Read Errors, Features Not
Accessible While Driving, Navigation Radio Resets Upon Startup (Update Navigation Radio
Software)
Models:
2006-2008 Buick Lucerne 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008
Chevrolet Equinox 2007-2008 GMC Acadia 2007-2008 Pontiac Torrent 2007-2008 Saturn
OUTLOOK, VUE All Equipped with Navigation Radio (RPOs U3R, UZR, U3U, UVB)
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada only.
Supercede: This bulletin is being revised to remove the NAV Disc Center Website information.
Please discard Corporate Bulletin Number 08-08-44-013D (Section 08 - Body and Accessories).
Note
If the vehicle has a 2008 MY radio and the software version is 100M or higher (e.g. 100N) for the
SuperNav navigation system (Escalades) or 100F or higher (e.g. 100G) for the BlackTie navigation
systems (Lucerne, Enclave, Equinox, Acadia, Torrent, Outlook, and VUE), the
improvements/corrections offered via update disc 20774148 are already installed and this update is
not required. The screen will display the following message "The disc installed is not a MAP DVD".
THIS IS NOT AN ERROR MESSAGE.
Condition
Customers may comment on any of the following conditions:
- The Navigation Radio display intermittently goes blank or turns black/off after switching video
sources. This most commonly occurs when the shift lever is transitioned from PARK to REVERSE
to DRIVE (or vice versa). Other possibilities include switching to DVD movie or Rear AUX (if
equipped).
- The Navigation Radio screen may intermittently freeze, lock up or display "MAP DVD Read Error"
messages.
- Some features may not be accessible while driving. This includes scrolling lists, address book and
navigation related entries (i.e. entering a destination).
- The Navigation Radio, upon startup, will continue to display the vehicle logo repeatedly. This
condition occurs when the vehicle language has been changed, using the Driver Information
Center (DIC), in the previous ignition cycle.
Cause
These conditions may be caused by software anomalies.
Parts Information (S/W included on disc)
Navigation software update discs are for the dealer to update the Navigation Radio software only.
They DO NOT update or replace the navigation map
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 > Navigation
Radio - Intermittent Blank/Black Screen > Page 14523
disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited
supply of these discs available. Do not order these discs for stock. Do not give the software update
disc to the customer. Navigation software discs may be used to reprogram more than one vehicle.
The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer
will cost $50 (USD). Refer to Corporate Bulletin Number 06-08-44-012C for additional information
on how to obtain AVN software update discs.
GM Navigation Disc Center Contact Information
Note
Navigation Radio Software Update Discs are no longer available via the Web.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Correction
Correction
Technicians are to update the Navigation Radio software using a software update disc, P/N
20774148. The software update disc is to be obtained from the GM Navigation Disc Center, using
the contact information below. Follow one of the two procedures below as appropriate for the
vehicle you are working on.
Navigation Radio Software Update For Cadillac Escalade Models 2007-2008
Note If the radio has software calibration 100M (2008 MY radios or earlier) or higher (e.g. 100N,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD". THIS IS NOT AN ERROR MESSAGE. To verify the software version follow steps 1
and 2 below.
Important For the condition regarding features not accessible while driving, this will only be
addressed in 2007 and 2008 model year Cadillac Escalade vehicles.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 > Navigation
Radio - Intermittent Blank/Black Screen > Page 14524
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the CONFIG and SEEK UP buttons (1)
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above which shows the two buttons that need to be pressed. The navigation
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100M (2008 MY or earlier) or higher, the radio has the latest
navigation software available and no update is
necessary. However, if the string of letters across the screen are NON-ASCII letters, this indicates
an internal communication problem with the RADIO. Refer to the Diagnostic Starting Point-Cellular,
Entertainment, and Navigation procedure to begin the diagnosis of the customer concern. For all
other navigation software versions proceed to step four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Eject the map disc from the top map DVD slot, callout (2) in the illustration above, if present.
Load the software update disc, P/N 20774148, into
the top map DVD slot.
5. The display will show "Update in Progress" and upon successful software upgrade, the screen
will transition to a blue screen with "The disc
installed is not a MAP DVD" displayed on the screen. It will take approximately five minutes to load
the new software. Eject the software update disc from the top map DVD slot and retain at your
dealership.
6. Confirm that the new navigation software version is 100M using the procedure in step two
above. 7. Install the customer's original map disc, if it was present. If the customer concern was
related to limitations while driving, confirm that the "Limit
Features While Driving" feature is turned off by pressing the CONFIG button followed by the Radio
tab and "Limit Features While Driving" tab. "Limit Features While Driving" should be unselected to
match the customer's preference.
8. Verify proper operation of the Navigation Radio.
Navigation Radio Software Update For All Other Vehicles (2007-2008 Chevrolet Equinox, Pontiac
Torrent; 2007-2008 GMC Acadia, Saturn OUTLOOK, Saturn VUE 2008 Buick Enclave and
2006-2008 Buick Lucerne)
Note If the radio has software calibration 100F (2008 MY radios or earlier) or higher (e.g. 100G,
etc.), the software corrections contained on the update disc 20774148 are already installed and this
update is not required. The screen will display the following message "The disc installed is not a
MAP DVD" THIS IS NOT AN ERROR MESSAGE. To verify the software version follow step 1 and
2 below.
1. Start the engine, with the gear shift in PARK, wait until the audio or navigation screen is
displayed after the opening screen (you may have to press
the OK button on the Caution screen).
2. Proceed to the FM audio screen and confirm the current navigation software version by pressing
the MENU and SEEK UP (1) buttons
simultaneously. If the screen switches, select FM to display the software version. Performing this
operation may take a couple of attempts for the radio to detect the simultaneous button press.
Refer to the illustration above, which shows the two buttons that need to be pressed. The
navigation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-013E > Jul > 09 > Navigation
Radio - Intermittent Blank/Black Screen > Page 14525
software version is the first four characters, reading from the left, located in the middle of the
screen.
3. If the navigation software version is 100F (2008 MY radios or earlier) or higher, the software
corrections contained on the update disc 20774148
are already installed and this update is not required. However, if the string of letters across the
screen are NON-ASCII letters, this indicates an internal communication problem with the RADIO.
Refer to the Diagnostic Starting Point-Cellular, Entertainment, and Navigation procedure to begin
the diagnosis of the customer concern. For all other navigation software versions proceed to step
four to continue the software update.
Important Do not turn off the power or remove the update disc while the software update is in
progress.
Important This software update procedure will erase the customer's Address and Destination
entries from memory.
4. Open the front display by pressing and holding the EJECT (1) button for approximately 15
seconds. Eject the map disc from the revealed map
DVD slot by pressing the EJECT (2) button located beneath the revealed map DVD slot. Load the
software update disc, P/N 20774148, in map drive (3).
5. Close the front display by using both hands at the four corners of the display until the display fits
securely into the radio. Do not push on the touch
screen to close. The display will show "Update in Progress" and upon successful software update,
the screen will transition to a blue screen with "The disc installed is not a MAP DVD" displayed on
the screen. It will take approximately five minutes to load the new software.
6. Confirm that the new navigation software version is either 101B or 100F using the procedure in
step two above. 7. Verify proper operation of the Navigation Radio.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs
Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl
Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips
Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips
INFORMATION
Bulletin No.: 08-08-44-010F
Date: March 09, 2009
Subject: Navigation Radio Diagnostic Tips
Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior
HUMMER H2, H3 2008 and Prior Saab 9-7X
All Equipped with Navigation Radio
Supercede:
This bulletin is being revised to update the model years involved, the radio part number list, remove
the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin
Number 08-08-44-010E (Section 08 - Body and Accessories).
Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test
as defective. In many cases, published SI documents were available to correct the condition
without the need for an exchange unit. The following Diagnostic Tips may assist with the proper
diagnosis and repair of Navigation Radio Concerns.
Note
For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction
through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and
Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow
the normal process and contact an authorized Electronic Service Center (ESC) for assistance.
For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the
returned radio. Be sure to document the customer's concern in detail, including unusual noises and
what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO.
Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly.
Note
Navigation Radios with physical damage (for example: shattered displays, impact damage to the
radio face and fluid damage) must be reviewed with the District Service Manager for appropriate
coverage prior to replacing the radio. The dealership must note the District Service Manager's
approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT
disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the
dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate
Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters.
Getting Started
Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin
Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD)
Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate
Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find
the corresponding Diagnostic Tips Review.
Printing This Document
To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the
arrows at the top of the screen to scroll left and right through the bulletin to identify the correct
pages containing the questions. With the pages identified, click on the Print button at the top left. In
the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print
pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in,
click the Print box at the bottom of the pop-up box.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14534
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14535
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14536
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14537
Diagnostic Tips Review Table
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14538
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14539
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14540
Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14541
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14542
Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14543
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14544
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14545
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14546
Diagnostic Tips Review # 3 - Denso Navigation Radios
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14547
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14548
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14549
Diagnostic Tips Review # 4 - Denso legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14550
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14551
Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information
Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference
Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation
Radio - Adaptation After Radio/Battery R&R;
Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After
Radio/Battery R&R;
INFORMATION
Bulletin No.: 08-08-44-023
Date: June 18, 2008
Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio
Replacement, Power Loss Or Battery Replacement
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
with Navigation Radio
The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may
not display the vehicle location icon on the map accurately after a radio or battery has been
replaced or after battery power has been removed from the radio. The vehicle location icon
accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red
line through it.
The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed
signals stored when the battery power is removed from the radio. The Navigation radio continually
uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned
accurately on the displayed map. There may be periods of time during a drive cycle when the GPS
signal may not be available and the vehicle location icon still appears to be accurate. This is due to
the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if
the radio had received a good GPS signal earlier in the drive cycle.
Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may
be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while
the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this
condition.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications
Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call
Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 14568
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-026 > Nov > 07 > Navigation
System - Obsolete Data/Voice Commands Inop.
Navigation System: All Technical Service Bulletins Navigation System - Obsolete Data/Voice
Commands Inop.
Bulletin No.: 07-08-44-026
Date: November 01, 2007
TECHNICAL
Subject: Navigation System Has Old Map Data And/Or Voice Recognition Commands Do Not Work
(Install 2008 Model Year Map Disc)
Models: 2008 Buick Lucerne 2008 Chevrolet Equinox 2008 GMC Acadia 2008 Pontiac Torrent
2008 Saturn OUTLOOK, VUE
with Navigation Radio (RPO U3U Equinox, Lucerne, Torrent, VUE) (RPO U3R or UZR Acadia,
Enclave, OUTLOOK)
Attention:
This condition affects a limited number of 2008 model year vehicles with a navigation radio that is
being used with a 2007 model year map disc, P/N 10396714.
Condition
Some customers may comment on the following conditions:
The navigation radio may display map data that is obsolete.
The navigation radio voice recognition commands do not work. These system commands are:
System Help
Display Day Mode
Display Night Mode
Display Auto Mode
This condition is NOT to be confused with the condition of the OnStar(R) voice recognition
commands not working. That is a different condition and is corrected by activating OnStar(R)
personal calling, NOT by using a 2008 model year map disc.
Correction
Technicians are not to replace the navigation radio for any of the conditions listed above. Use the
following procedure to correct these conditions:
Refer to the VIN of the vehicle to verify that it is a 2008 model. The tenth character of the VIN must
be an 8.
If the vehicle is a 2008 model, verify that the map disc loaded in the radio is actually a 2007 model
year disc, part number 10396714.
If the vehicle is a 2008 model and has a 2007 model year map disc, contact the Navigation (NAV)
Disc Center and request a new 2008 model year map disc, P/N 25880099.
Install the new map disc into the navigation radio and verify proper operation of the navigation
system. The conditions listed above will be corrected automatically the first time the new map disc
is inserted into the radio. No setup procedure is required.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-026 > Nov > 07 > Navigation
System - Obsolete Data/Voice Commands Inop. > Page 14573
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information
Navigation System: All Technical Service Bulletins OnStar(R) - Language Change Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14578
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14579
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14580
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14581
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation
System - Software/DVD Update Program > Page 14591
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14596
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14597
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 14598
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) Availability for Hearing Impaired > Page 14603
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14612
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14613
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14614
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14615
Diagnostic Tips Review Table
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14616
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14617
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14618
Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14619
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14620
Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14621
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14622
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14623
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14624
Diagnostic Tips Review # 3 - Denso Navigation Radios
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14625
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14626
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14627
Diagnostic Tips Review # 4 - Denso legacy Navigation Radio
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14628
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation
Radio - Diagnostic Tips > Page 14629
Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14646
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14647
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14648
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-009B > Jun > 07 > OnStar(R) Language Change Information > Page 14649
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning
Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning
Sensor > Component Information > Locations > Page 14654
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier,
Sound System > Component Information > Diagrams
Amplifier: Diagrams
Component Connector End Views
Amplifier X1 (U65)
Amplifier X2 (U65)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier,
Sound System > Component Information > Diagrams > Page 14659
Amplifier X3 (U65)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier,
Sound System > Component Information > Diagrams > Page 14660
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier,
Sound System > Component Information > Diagrams > Page 14661
Amplifier: Service and Repair
Radio Speaker Amplifier Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Service and Repair
Compact Disc Player (CD): Service and Repair
Compact Disc Care and Cleaning
Care of CDs
Handle CDs carefully. Store them in their original cases or other protective cases and away from
direct sunlight and dust. The CD player scans the bottom surface of the disc. If the surface of a CD
is damaged, such as cracked, broken, scratched, or wrinkled labeling, the CD will not play properly
or not at all. If the surface of a CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth
in a mild, neutral detergent solution mixed with water, and clean it. Make sure the wiping process
starts from the center to the edge. Do not touch the bottom side of a CD while handling it. This
could damage the surface. Pick up CDs by grasping the outer edges or the edge of the hole and
the outer edge.
Care of the CD Player
The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the
internal lens of the CD optics with lubricants.
Stuck CDs
Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is
stuck, and removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the
radio.
Labeling CDs
Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD
player. Try labeling the top of the discs with a soft magic marker instead.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: >
08-08-44-008A > Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting
Radio Receiver: Customer Interest Audio System - XM Radio(R) Won't Retain Station Setting
TECHNICAL
Bulletin No.: 08-08-44-008A
Date: April 25, 2008
Subject: XM Radio Does Not Retain Station Setting From Previous Key Cycle and Changes To
Channel 1, The Preview Channel, at Vehicle Start-up (Replace Digital Radio Receiver Assembly)
Models: 2008 Buick Enclave, Lucerne 2008 Cadillac DTS, Escalade Models, SRX 2008 Chevrolet
Avalanche, Equinox, Impala, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia 2008 GMC
Sierra, Yukon Models 2008 Pontiac Torrent 2008 HUMMER H2, H2 SUT 2007-2008 Saturn
OUTLOOK 2008 Saturn VUE 2008 Suzuki XL-7
with XM Satellite Radio (RPO U2K)
Supercede:
This bulletin is being revised to add the Suzuki XL-7 model. Please discard Corporate Bulletin
Number 08-08-44-008 (Section 08 - Body & Accessories).
Condition
Some customers may comment that the XM radio does not retain the station setting from the
previous key cycle and changes to channel 1 at vehicle start-up. After start-up, the XM radio will be
on the preview channel 1.
Cause
A software anomaly in the Digital Radio Receiver Assembly may cause this condition.
Correction
Technicians are to replace the Digital Radio Receiver Assembly with an updated design part. Refer
to the Digital Radio Receiver Replacement procedure in SI. Also refer to the Digital Radio Receiver
Setup procedure in SI for additional information.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: >
08-08-44-008A > Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting > Page 14674
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver:
> 08-08-44-008A > Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting
Radio Receiver: All Technical Service Bulletins Audio System - XM Radio(R) Won't Retain Station
Setting
TECHNICAL
Bulletin No.: 08-08-44-008A
Date: April 25, 2008
Subject: XM Radio Does Not Retain Station Setting From Previous Key Cycle and Changes To
Channel 1, The Preview Channel, at Vehicle Start-up (Replace Digital Radio Receiver Assembly)
Models: 2008 Buick Enclave, Lucerne 2008 Cadillac DTS, Escalade Models, SRX 2008 Chevrolet
Avalanche, Equinox, Impala, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia 2008 GMC
Sierra, Yukon Models 2008 Pontiac Torrent 2008 HUMMER H2, H2 SUT 2007-2008 Saturn
OUTLOOK 2008 Saturn VUE 2008 Suzuki XL-7
with XM Satellite Radio (RPO U2K)
Supercede:
This bulletin is being revised to add the Suzuki XL-7 model. Please discard Corporate Bulletin
Number 08-08-44-008 (Section 08 - Body & Accessories).
Condition
Some customers may comment that the XM radio does not retain the station setting from the
previous key cycle and changes to channel 1 at vehicle start-up. After start-up, the XM radio will be
on the preview channel 1.
Cause
A software anomaly in the Digital Radio Receiver Assembly may cause this condition.
Correction
Technicians are to replace the Digital Radio Receiver Assembly with an updated design part. Refer
to the Digital Radio Receiver Replacement procedure in SI. Also refer to the Digital Radio Receiver
Setup procedure in SI for additional information.
Parts Information
Warranty Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver:
> 08-08-44-008A > Apr > 08 > Audio System - XM Radio(R) Won't Retain Station Setting > Page 14680
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14689
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R)
Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using
OnStar(R)
TECHNICAL
Bulletin No.: 07-08-46-002D
Date: July 29, 2009
Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise
Suppression Filter)
Models:
2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3
2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update the Warranty Information. Please discard
Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories).
Condition
Some customers may comment on an audio whine coming from the radio speakers when using the
OnStar(R) system. The amplitude and frequency of the whine will change with an increase or
decrease in engine speed.
Cause
This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication
Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio.
Correction
Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery
voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached
wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the
single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single
yellow wire into the battery voltage circuit toward the fuse and the black wire to ground.
Important The noise suppression filter is polarity sensitive. The filter is designed to be most
effective when the end with the capacitor ground is connected towards the source of the electrical
noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting
the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing
the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding
the capacitor lead.
Parts Information
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14695
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering
Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams
Speaker: Diagrams
Component Connector End Views - Continued
Speaker - Left Front
Speaker - Left Front (Tweeter)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 14703
Speaker - Left Rear
Speaker - Right Front
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 14704
Speaker - Right Front (Tweeter)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 14705
Speaker - Right Rear
Speaker - Subwoofer (U65)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 14706
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement
Speaker: Service and Repair Radio Front Side Door Speaker Replacement
Radio Front Side Door Speaker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 14709
Speaker: Service and Repair Radio Front Side Door Upper Speaker Replacement
Radio Front Side Door Upper Speaker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 14710
Speaker: Service and Repair Radio Rear Speaker Replacement
Radio Rear Speaker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Radio Front Side Door Speaker Replacement > Page 14711
Speaker: Service and Repair Radio Rear Side Door Speaker Replacement
Radio Rear Side Door Speaker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Accessory Delay Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 14720
Alarm Module: Diagrams
Component Connector End Views - Continued
Theft Deterrent Module (TDM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft
Deterrent Malfunction
Alarm Module: Testing and Inspection Content Theft Deterrent Malfunction
Content Theft Deterrent Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The content theft deterrent (CTD) system is a software based system in which the body control
module (BCM) actively monitors certain inputs to determine if unauthorized vehicle access is being
attempted. Based on inputs such as the door ajar switches, the rear compartment ajar switch, and
the hood ajar switch, the BCM determines whether a CTD alarm is warranted. If unauthorized
access is being detected, the BCM will pulse the vehicle horn and flash the turn signals as a means
of theft deterrence.
Circuit/System Verification
1. Individually open and close each vehicle door while observing the door ajar indicator/message.
The indicator/message should accurately transition
between the door ajar and door closed state when each door is opened and closed.
^ If the door ajar indicator/message does not properly transition when each door is opened and
closed, refer to Door Ajar Indicator Malfunction. See: Body and Frame/Locks/Testing and
Inspection/Symptom Related Diagnostic Procedures/Door Ajar Indicator Malfunction
2. Open and close the liftgate while observing the liftgate ajar indicator/message. The
indicator/message should accurately transition between the
liftgate ajar and liftgate closed state when the trunk is opened and closed.
^ If the liftgate ajar indicator/message does not properly transition when the liftgate is opened and
closed, refer to Liftgate Ajar Indicator Malfunction.
3. Completely lower the driver door window and close all vehicle doors. 4. Ignition OFF, arm the
CTD system using the keyless entry system by pressing the transmitter LOCK button twice. Verify
the scan tool CTD Status
parameter displays Armed.
^ If the parameter does not equal the specified value, refer to Keyless Entry System Inoperative.
See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related
Diagnostic Procedures/Keyless Entry System Inoperative
5. Without disarming the system, reach in through the open driver window, unlock and open the
driver door. Verify the scan tool CTD Status
parameter displays Alarm Active.
^ If the parameter does not equal the specified value, replace the BCM.
6. With the door open, verify the vehicle horn is pulsing and the exterior lamps are flashing.
^ If the horn is not pulsing, refer to Horns Malfunction. See: Lighting and Horns/Horn/Testing and
Inspection/Symptom Related Diagnostic Procedures/Horns Malfunction
^ If the exterior lights are not flashing, refer to Turn Signal Lamps and/or Indicators Malfunction.
See: Lighting and Horns/Testing and Inspection/Symptom Related Diagnostic Procedures/Turn
Signal Lamps and/or Indicators Malfunction
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Content Theft
Deterrent Malfunction > Page 14723
Alarm Module: Testing and Inspection Security Indicator Malfunction
Security Indicator Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
The security indicator is controlled by the Body Control Module (BCM) based on commands from
the immobilizer system or the Content Theft Deterrent (CTD) system. With the ignition OFF, the
security indicator is commanded by the CTD system. With the ignition ON, the security indicator is
commanded by the immobilizer system.
The security indicator is located in the Instrument Panel Cluster (IPC) and is supplied B+ at all
times. When the immobilizer or CTD system requests the indicator be commanded ON, the BCM
grounds the security indicator control circuit, illuminating the indicator.
Circuit/System Verification
Ignition ON, command the security indicator ON and OFF with a scan tool. The security indicator
should turn ON and OFF when changing between the commanded states.
Circuit/System Testing
1. Ignition OFF, disconnect the harness connector at the IPC. 2. Connect a test lamp between the
control circuit terminal 16 and B+. 3. Command the security indicator ON and OFF with a scan tool.
The test lamp should turn ON and OFF when changing between the commanded
states.
^ If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests
normal, replace the BCM.
^ If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the BCM.
4. If all circuits test normal, replace the IPC.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Testing and Inspection > Page 14724
Alarm Module: Service and Repair
Theft Deterrent Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations
Central Control Module: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 3 of 3
1 - Instrument Panel Cluster (IPC) 2 - Instrument Panel Trim 3 - Vehicle Communication Interface
Module (VCIM) (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Page 14728
Central Control Module: Diagrams
Component Connector End Views - Continued
Vehicle Communication Interface Module (VCIM) X1 (UE1)
Vehicle Communication Interface Module (VCIM) X2 (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Page 14729
Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Locations > Page 14730
Vehicle Communication Interface Module (VCIM) Battery (UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Service and Repair > Communication Interface Module
Battery Replacement
Central Control Module: Service and Repair Communication Interface Module Battery Replacement
Communication Interface Module Battery Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Central Control Module > Component Information > Service and Repair > Communication Interface Module
Battery Replacement > Page 14733
Central Control Module: Service and Repair Communication Interface Module Replacement
Communication Interface Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14742
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14743
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 >
Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 14744
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R)
Technical Service Bulletin # 10037 Date: 100420
Campaign - Unwanted Repeat Calls to OnStar(R)
CUSTOMER SATISFACTION
Bulletin No.: 10037
Date: April 20, 2010
Subject: 10037 - Unwanted Repeat Calls to OnStar(R)
Models:
2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick
LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave
2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac
Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS
2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX,
STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado
2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet
Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo
2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009
Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008
GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007
GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008
HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006
Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent
2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION
2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO
UE1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 14750
THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011.
Condition
Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which
the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the
vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls,
and Automatic Crash Notification calls will also fail to establish a data connection with the
OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the
customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial
customer data such as vehicle identification and location.
Correction
Dealers/retailers are to replace the OnStar(R) module (VCIM).
Vehicles Involved
Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within
these VIN breakpoints:
Note:
Some model years/models have only one vehicle involved.
Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using
GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using
GWM). Not all vehicles within the above breakpoints may be involved.
For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete
vehicle identification number, customer name, and address information has been prepared and will
be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers
will not have a report available if they have no involved vehicles currently assigned.
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this program is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
program.
Parts Information
US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft
Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin
number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O.
number, and the current vehicle mileage.
Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS
Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle
mileage.
DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND
AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE
TECHNICAL ASSISTANCE CENTER (TAC).
Courtesy Transportation
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranties. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle
service or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for
dealers/retailers using GWM - submit as Net Item under the repair labor code.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 14751
* Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module
exchange.
Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for
the module exchange.
** The $25 represents the additional net amount allowed for the module exchange.
*** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by
Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative
allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance
under Administrative Time.
Customer Notification
OnStar will notify customers of this program on their vehicle.
Dealer Program Responsibility
All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held
and inspected/repaired per the service procedure of this program bulletin before customers take
possession of these vehicles.
Dealers/retailers are to service all vehicles subject to this program at no charge to customers,
regardless of mileage, age of vehicle, or ownership, through April 30, 2011.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer/retailer listing, are to be contacted by the
dealer/retailer. Arrangements are to be made to make the required correction according to the
instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for
your use in contacting customers. Program follow-up cards should not be used for this purpose,
since the customer may not as yet have received the notification letter.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to
OnStar(R) > Page 14752
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your
dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure
the program correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
Service Procedure
Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no
bearing on this specific issue.
1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module (VCIM)
in SI). Refer to SI for module removal instructions.
Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth
devices that have not been paired to the new VCIM will not function properly.
2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or
Vehicle Communication Interface Module
(VCIM) in SI). Refer to SI for module installation instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing
Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing
Impaired > Page 14757
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired
Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for
Hearing Impaired
INFORMATION
Bulletin No.: 06-08-46-005B
Date: February 11, 2010
Subject: Availability of OnStar(R) for Hearing Impaired
Models:
2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007
Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except
2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra
Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped
vehicles, additional models and model years. Please discard Corporate Bulletin Number
06-08-46-005A (Section 08 - Body and Accessories).
Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers.
Note
On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code
UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled.
OnStar with Text Telephone Capability (TTY)
General Motors is pleased to announce that the safety and security of OnStar is now available to
our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as
well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability
to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN
lookup Tool. Additional information may be found by referring to www.onstar.com/tty.
TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access
to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency
button. The keypad provides a means to communicate by allowing customers to type messages
back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free
Calling feature. A TTY is required at both ends of the conversation in order to communicate.
OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY.
The Reimbursement Program
This equipment will be made available to eligible customers through GM Mobility and OnStar(R).
Under this program, the customer must complete a GM Mobility application form. To take
advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease
and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form
submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic
reimbursement directly from GM Mobility. Saab dealers will receive a check directly from
OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center.
How to Order
To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com.
The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness,
the TTY device, installation/Tech 2(R) programming instructions and owner's guide.
Warranty Information
The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is
covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited
Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard
GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft
Electronics. Contact AutoCraft Electronics or via the web.
Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through
normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Communications Control Module: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired >
Page 14763
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14772
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call
Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported
During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 14777
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues
Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14782
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 14783
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number
Incorrect/Incorrectly Assigned
INFORMATION
Bulletin No.: 05-08-46-004C
Date: December 23, 2010
Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another
Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System
Models:
2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1)
Supercede: This bulletin is being revised to update model years up to 2011. Please discard
Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories).
During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone
number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these
concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the
OnStar(R) phone number.
Service Procedure
1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech
2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section.
Then select the Special Functions menu.
For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular
Communication section. Select Module Setup and then Vehicle Communication Interface Module.
3. Locate the Program Phone Number prompt and select it. The original phone number will be
displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance
Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a
time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft
key at the base of the screen for Done once these numbers have been changed on the screen. 7.
Press the Soft key for Done again. The area code or new phone number has now been
programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the
blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call
center. If applicable, make sure the
Hands-Free Calling (HFC) works properly by making a phone call.
10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at
TAC with the results. Dealers in Canada should
submit case closing information through the GM infoNET.
Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited
is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If
the procedure above does not resolve the condition, you must contact TAC for further assistance.
This diagnostic approach was developed specifically for this condition and should not automatically
be used for other vehicles with similar symptoms.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab Models)
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned
> Page 14789
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference
Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
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Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R)
Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported
During Call
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position
Reported During Call
Bulletin No.: 02-08-46-006C
Date: January 08, 2008
INFORMATION
Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During
OnStar(R) Call
Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R)
Supercede:
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number
02-08-46-006B (Section 08 - Body and Accessories).
A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle
reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified
via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able
to identify this inaccurate location condition. Customers will then be notified through the mail by
OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R)
will instruct the customer to return to the dealership to have this condition corrected.
It is not necessary to reconfigure the vehicle after the following procedure.
In order to correct this condition you must cycle power to the OnStar(R) system. This can be done
by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R)
module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery.
The power needs to be removed from the system for approximately 15 minutes.
After completing this procedure the vehicle should be taken to an area with an unobstructed view of
the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to
reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue
OnStar(R) button and ask the advisor to verify the GPS position.
If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and
Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the
concern. If the normal diagnostics lead to module replacement you will need to contact Technical
Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the
diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out
within 24 hours and a pre-paid return package label will be included for returning the faulty part. By
returning the faulty part you will avoid a significant non-return core charge.
Warranty Information (excluding Saab US Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab US Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported
During Call > Page 14806
For vehicles repaired under warranty use, the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free
Issues
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands
Free Issues
Bulletin No.: 02-08-46-007C
Date: November 19, 2007
INFORMATION
Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling
Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes
Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008
HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X
with OnStar(R) System (RPO UE1)
Supercede:
This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS
signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM
needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body
& Accessories).
If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be
made aware of the digital upgrade program per the latest version of Service Bulletin #
05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be
deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada.
If the vehicle has recently been upgraded or has had a service replacement unit installed, this
bulletin may not be applicable.
Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the
Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is
internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface
Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is
unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or
the inability to add Hands-Free calling minutes.
Customer Notification
OnStar(R) will notify the customer by mail with instructions to contact their dealership service
department.
Dealer Action
Not all vehicles will require VIU/VCIM replacement.
The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable,
simply connect the Tech2(R) and using the GPS information data display option, observe the GPS
date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the
GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time
stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and
may be recoverable by performing the following power-up reset.
To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The
preferred methods, in order, of initiating the reset are outlined below.
Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the
applicable Service Information schematics for the appropriate fuse).
The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is
contained.
The least preferable method is to remove the negative terminal of the vehicle battery. This will not
only initiate the power-up reset, but it may also result in the loss of radio presets and other stored
personalization information/settings in other modules as well.
After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will
require an acquisition of the GPS signal in order to gain the proper date and time.
Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky.
First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R)
Technical Advisor to activate the GPS recovery process. This should take approximately 10
minutes. Continue to
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free
Issues > Page 14811
monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time
displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time
zones relationship to GMT.
If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure
to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU,
Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the
vehicle with an OnStar® advisor.
OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use
of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R).
The configuration and set-up procedure is a two-step process that must be completed step-by-step
without interruption or delay in between each step. This procedure enables an automated activation
without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it
may take up to 24 hours for all OnStar(R) services to be fully activated.
How to Order Parts
If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced,
dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this
bulletin number. Canadian dealers should contact MASS Electronics.
Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement
approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the
subject vehicle is a candidate for a replacement VIU/VCIM.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use the table.
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free
Issues > Page 14812
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14817
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14818
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14819
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14820
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of
Cloth/Vinyl Roofs
INFORMATION
Bulletin No.: 02-08-44-007D
Date: May 12, 2009
Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R)
Systems
Models:
2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009
HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1)
..............................................................................................................................................................
.................................................................................. Supercede: This bulletin is being revised to
include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section
08 - Body and Accessories).
..............................................................................................................................................................
..................................................................................
Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio
option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be
negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result
from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the
antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised
either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their
current locations. Relocating the antennas may result in a performance degradation.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference
Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device
Interference Information
INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008
Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services
Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER
H2, H3 Models 2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)
This bulletin is being issued to provide dealer service personnel with information regarding
aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to
OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.
Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not
limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices,
interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call)
by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data
for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail.
These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or
information gathering. When these devices are requesting data, OnStar(R) is designed not to
interfere with any data request being made by these devices as required by OBD II regulations.
The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only
be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some
cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.
When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic
probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail,
verify that an aftermarket device was not present at the time of the requested probe. Regarding the
OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail
will consistently display a "yellow" indication in diagnostics section for all vehicle systems except
the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed
(i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume
following the removal or disconnecting of the off-board device.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R)
Communications
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R)
Communications
Bulletin No.: 00-08-46-004C
Date: January 17, 2008
INFORMATION
Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect
Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab)
with Digital OnStar(R) (RPO UE1)
Supercede:
This bulletin is being revised to add models and model years. Please discard Corporate Bulletin
Number 00-08-46-004B (Section 08 - Body and Accessories).
When servicing any of the above models and a battery cable is disconnected or power to the
OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the
following procedure must be performed to verify proper Global Positioning System (GPS) function.
Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles.
Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module
has a unique identification number. The VCIM has a specific Station Identification (STID). This
identification number is used by the National Cellular Telephone Network and OnStar(R) systems
and is stored in General Motors Vehicle History files by VIN.
After completing ALL repairs to the vehicle you must perform the following procedure:
Move the vehicle into an open area of the service lot.
Sit in the vehicle with the engine running and the radio turned on for five minutes.
Press the OnStar(R) button in the vehicle.
When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle.
If the vehicle location is different than the location the OnStar(R) advisor gives contact GM
Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in
the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are
usually shipped out within 24 hours, and a pre-paid return package label will be included for
returning the faulty part. By returning the faulty part, you will avoid a non-return core charge.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information
Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change
Information
Bulletin No.: 05-08-46-009B
Date: June 29, 2007
INFORMATION
Subject: Language Change for OnStar(R) System (U.S. and Canada Only)
Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008
HUMMER H2, H3 2006-2008 Saab 9-7X
with OnStar(R) (RPO UE1)
Built After and Including VIN Breakpoints Listed Below (2006 MY Only)
Attention:
This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station
Identification (STID) Number in the following range: 16,000,000-17,000,000 or
20,000,000-21,999,999 or 23,500,001-26,000,000
Supercede:
This bulletin is being revised to update the service procedure and add a Canadian procedure.
Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body
and Accessories).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14838
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14839
Built After and Including the VIN Breakpoints shown.
The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change
the default English voice recognition to French or Spanish.
Changing the language of the OnStar(R) system will change the following features to the language
you select:
Voice recognition command prompts will be played in the language selected.
The voice recognition system will only recognize commands given in the selected language.
Once completed, this process completely changes all voice recognition and voice commands of the
OnStar(R) system. The process will need to be repeated in its entirety to change to a different
language, including English.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14840
Method 1
Method 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 05-08-46-009B > Jun > 07 > OnStar(R) - Language Change Information > Page
14841
Method 3
The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System
(SPS) to change the voice recognition system. However, there are three ways to change the
language.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Entertainment System Control Module > Component Information > Diagrams
Entertainment System Control Module: Diagrams
Component Connector End Views - Continued
Infrared Transmitter Module (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14856
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14857
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: >
09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14858
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14864
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14865
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14866
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules
Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 14875
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 14876
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's
Set By Various Control Modules > Page 14877
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules
Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control
Modules
TECHNICAL
Bulletin No.: 09-06-03-004D
Date: December 08, 2010
Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle
Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion
(Disconnect Affected Connector and Apply Dielectric Lubricant)
Models:
2011 and Prior GM Passenger Cars and Trucks
Attention:
This repair can be applied to ANY electrical connection including, but not limited to: lighting, body
electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the
point where it prevents the full engagement of sealed connectors. A light coating on the terminal
surfaces is sufficient to correct the condition.
Supercede: This bulletin is being revised to update the Attention statement and add the 2011
model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System).
Condition
Some customers may comment on any of the following conditions:
- An intermittent no crank/no start
- Intermittent malfunction indicator lamp (MIL) illumination
- Intermittent service lamp illumination
- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.
Cause
This condition may be caused by a buildup of nonconductive insulating oxidized debris known as
fretting corrosion, occurring between two electrical contact surfaces of the connection or connector.
This may be caused by any of the following conditions:
- Vibration
- Thermal cycling
- Poor connection/terminal retention
- Micro motion
- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent
connections.
On high current power circuits this condition may cause permanent increases in the resistance and
may cause a device to become inoperative.
Representative List of Control Modules and Components
The following is only a representative list of control modules and components that may be affected
by this connection or connector condition and DOES NOT include every possible module or
component for every vehicle.
- Blower Control Module
- Body Control Module (BCM)
- Communication Interface Module (CIM)
- Cooling Fan Control Module
- Electronic Brake Control Module (EBCM)
- Electronic Brake and Traction Control Module (EBTCM)
- Electronic Suspension Control (ESC) Module
- Engine Control Module (ECM)
- Heating, Ventilation and Air Conditioning (HVAC) Control Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14883
- HVAC Actuator
- Inflatable Restraint Sensing and Diagnostic Module (SDM)
- Any AIR BAG module
- Seatbelt Lap Anchor Pretensioner
- Seatbelt Retractor Pretensioner
- An SIR system connection or connector condition resulting in the following DTCs being set:
B0015, B0016, B0019, B0020, B0022, or B0023
- Powertrain Control Module (PCM)
- Remote Control Door Lock Receiver (RCDLR)
- Transmission Control Module (TCM)
Correction
Important DO NOT replace the control module, wiring or component for the following conditions:
- The condition is intermittent and cannot be duplicated.
- The condition is present and by disconnecting and reconnecting the connector the condition can
no longer be duplicated.
Use the following procedure to correct the conditions listed above.
1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any
existing history or current DTCs from all of the
control modules (refer to SI).
‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the
connector(s) of the control module/component
which may be causing the condition (refer to SI).
‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control
module/component which may be causing the
condition (refer to SI).
2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component
Connector End Views and Component Locator
documents to locate and disconnect the affected harness connector(s) which are causing the
condition.
Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the
actual electrical contact is being made. In less severe cases it may be unable to be seen or
identified without the use of a magnifying glass.
Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown,
as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush
that is dedicated to the repair of the conditions in this bulletin.
3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side
and the harness side of the affected connector(s).
4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present.
5. Attempt to duplicate the condition by using the following information:
- DTC Diagnostic Procedure
- Circuit/System Description
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Diagnostic Aids
- Circuit/System Verification
‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated,
then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).
Repair Order Documentation
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14884
Important The following information MUST be documented on the repair order. Failure to do so
may result in a chargeback.
- Customer vehicle condition.
- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or
Service Message.
- Was a DTC(s) set? If yes, specify which DTC(s) were set.
- After following the procedure contained within this bulletin, could the condition be duplicated?
‹› If the condition was not duplicated, then document the affected module/component connector
name and number on the repair order.
- If the condition was duplicated after the procedure contained within this bulletin was followed, and
additional diagnosis led to the replacement of a module or component, the SI Document ID
Number MUST be written on the repair order.
Parts Information
Alternate Distributor For All of North America
Note
NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada),
specified for use to correct the condition in this bulletin.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Warranty Information (excluding Saab Models)
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to:
Warranty Information (Saab Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 14885
For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon
the module/component connection that the dielectric lubricant was applied to refer to the table
above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Sensor > Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 14893
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent
Steering Wheel Button Activation
Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation
INFORMATION
Bulletin No.: 08-08-44-028
Date: August 28, 2008
Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio
Anomalies
Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior
HUMMER H2, H3 Models 2009 and Prior Saab 9-7X
All Vehicles with Steering Wheel Controls
This bulletin is being issued to provide a recommendation for vehicles with a customer concern of
the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or
radio muting or going silent when driving and turning the steering wheel.
The switches on the right hand side of the steering wheel are easily pressed and may inadvertently
be pressed when turning the steering wheel.
These concerns may be affected by the location of the steering wheel controls.
Recommendation
Do Not Replace The Radio
1. Please determine that the switch controls on the steering wheel are functioning correctly.
2. Ask the customer if their hand was in close proximity to the steering wheel controls when the
condition happened. Explain to the customer that bumping the controls would have caused this
undesired action. Explain to the customer the proper use and function of the steering wheel
controls.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement (Equinox)
Removal Procedure
1. Use a small flat-bladed tool to release the switch assembly from the steering wheel. 2.
Disconnect the cruise switch electrical harness connector from the switch.
Installation Procedure
1. Connect the switch electrical harness connector to the switch. Push in the connector until a click
is heard and pull back to confirm a positive
engagement.
2. Insert the cruise switch into the steering wheel and gently apply pressure to fasten the switch in
the opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component
Information > Service and Repair
Steering Mounted Controls Assembly: Service and Repair
Steering Wheel Control Switch Assembly Replacement (Equinox)
Removal Procedure
1. Use a small flat-bladed tool to release the switch assembly from the steering wheel. 2.
Disconnect the cruise switch electrical harness connector from the switch.
Installation Procedure
1. Connect the switch electrical harness connector to the switch. Push in the connector until a click
is heard and pull back to confirm a positive
engagement.
2. Insert the cruise switch into the steering wheel and gently apply pressure to fasten the switch in
the opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter >
Component Information > Locations
Steering Mounted Controls Transmitter: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Horn Switch 2 - Steering Wheel Control Switch - Right (UK3/K34) 3 - Steering Wheel Control
Switch - Left (UK3/K34)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter >
Component Information > Locations > Page 14907
Steering Mounted Controls Transmitter: Diagrams
Component Connector End Views - Continued
Steering Wheel Control Switch - Left
Steering Wheel Control Switch - Right (UK3)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter >
Component Information > Locations > Page 14908
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams
Trailer Connector: Diagrams
Component Connector End Views - Continued
Trailer Connector Adaptor (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams
Trailer Connector: Diagrams
Component Connector End Views - Continued
Trailer Connector Adaptor (V92)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module
Body Control Module: Technical Service Bulletins Body Controls - Unable To Reprogram Body
Control Module
INFORMATION
Bulletin No.: 09-08-47-001A
Date: June 14, 2010
Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not
Complete - Revised Reprogramming Instructions
Models:
2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV,
Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro
2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche,
Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet
Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8
2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS
Supercede: This bulletin is being revised to update the models and the model years. Please
discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories).
Some technicians may experience an unsuccessful body control module (BCM) reprogramming
event, when choosing the Reprogram ECU selection on the Service Programming System (SPS).
The technician may also notice that when attempting to reprogram the BCM again after this
incident has occurred, the BCM may not complete the programming event.
This condition may be caused by the following:
- A reprogramming event that was interrupted due to a lack of communication between the vehicle
and the TIS2WEB terminal.
- The vehicle experienced low system voltage during the reprogramming event.
Important Do not replace the BCM for this condition.
SPS Programming Process Selection
Perform this procedure first.
1. If reprogramming has failed during the initial reprogramming event, back out of the SPS
application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When
selecting the Programming Process , choose Replace and Program ECU , even though a new
BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS)
with the latest calibration available on TIS2WEB. Refer to the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page 14925
During programming, the battery voltage must be maintained within the proper range of 12-15
volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
BCM Still Fails to Reprogram
If the BCM still fails to reprogram perform this procedure:
1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following
modules/components for a minimum of 2 minutes:
- BCM
- EBCM
- ECM
- IS LPS (located in the left IP fusebox)
- TCM
3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to
turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace
and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using
the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to
the SPS procedures
in SI.
When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with
the latest software version.
When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software
version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page 14926
Body Control Module: Technical Service Bulletins Body Controls - Body Control Module (BCM)
Grounds
INFORMATION
Bulletin No.: 07-08-47-004C
Date: December 04, 2009
Subject: Information on Body Control Module (BCM) Grounds
Models:
2006-2010 Buick Lucerne 2007-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2009 Cadillac
SRX 2008-2010 Cadillac CTS 2006-2008 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala
2007-2009 Chevrolet Equinox 2008-2010 Chevrolet Express, Traverse 2007-2010 GMC Acadia
2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010
Saturn VUE 2008-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models, model years and information.
Please discard Corporate Bulletin Number 07-08-47-004B (Section 08 - Body & Accessories).
The purpose of this bulletin is to inform dealers of an issue that could cause internal module
damage to the Body Control Module (BCM).
The BCM may be damaged when the module is supplied with battery power and the ground path is
removed. You must remove the negative battery cable first before removing a BCM ground.
Issue 1
Below is a list of vehicles and the components that the BCM ground path passes through. The
negative battery cable must be removed when removing the components noted below.
- 2008-2010 HUMMER H2 (Instrument panel electrical center)
- 2008-2010 Saturn VUE (I/P splice pack)
Issue 2
It is important to note when removing a ring terminal ground, splice pack connector, or inline
harness connector for all the vehicles listed in the model section above, that it doesn't include a
BCM ground path. You must remove the negative battery cable if you determine that it is a BCM
ground path.
As an example: If the BCM grounds become disconnected, internal damage to the BCM will occur.
Other systems controlled by the BCM will also be affected, such as an inoperative or intermittent
condition in one or more of the following systems:
- Interior lighting will remain on or will not work
- Exterior lighting will remain on or will not work
- Remote keyless entry
- Door locks
- Power windows and mirrors
- Remote vehicle start
- Remote trunk release
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Body Controls - Unable To Reprogram Body Control Module > Page 14927
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14928
Body Control Module: Locations
Instrument Panel/Center Console Component Views
Lower Center Instrument Panel Components
1 - Body Control Module (BCM) 2 - Instrument Panel Harness 3 - Center Instrument Panel Support
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14929
Body Control Module: Diagrams
Component Connector End Views
Body Control Module (BCM) X1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14930
Body Control Module (BCM) X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14931
Body Control Module (BCM) X3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14932
Body Control Module (BCM) X4
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14933
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14934
Body Control Module (BCM) X5
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14935
Body Control Module (BCM) X6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14936
Body Control Module (BCM) X7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14937
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information
> Technical Service Bulletins > Page 14938
Body Control Module: Service and Repair
Body Control Module Replacement
Removal Procedure
Important: If data is not retrieved from the malfunctioning body control module (BCM), additional
time will be required to program the replacement BCM.
1. Retrieve data from the malfunctioning BCM. 2. Rotate the ignition switch to the OFF position.
3. Remove the radio bezel. 4. Disconnect the BCM electrical harnesses. 5. Remove the BCM from
the instrument panel (I/P) retainer:
1. Pry the BCM tabs from the locking tabs on the underside of the restraint. 2. Slide the BCM out of
the retainer.
Installation Procedure
1. Install the BCM. 2. Install the radio bezel. 3. Slide the BCM tabs into the slots in the I/P retainer
until the tabs lock into place. 4. Connect the electrical connectors. 5. Program a new or a
remanufactured BCM.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting
Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to
Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Fascia Grille Replacement
Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement
Fascia Grille Replacement
Removal Procedure
1. Remove the front fascia assembly (3). 2. Remove the front fascia support. 3. Remove the
radiator grille strap (2) from the back of the grille by depressing the grille strap fingers and pushing
through the front of the grille.
4. Remove the screw from the bottom center of the grille. 5. Remove the grille from the front fascia
by releasing the retainers around the perimeter of the grille.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Fascia Grille Replacement > Page 14947
1. Position the grille to the front fascia. 2. Install the grille to the front fascia by pushing in to secure
the retainers around the perimeter of the grille.
Notice: Refer to Fastener Notice.
3. Install the screw to the bottom center of the grille.
Tighten the screw to 2 N.m (18 lb in).
4. Install the radiator grille strap into the front fascia and grille by pushing the fingers on the strap
into the grille and fascia until fully secured. 5. Install the front fascia support. 6. Install the front
fascia assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Fascia Grille Replacement > Page 14948
Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement (Equinox)
Front Bumper Fascia Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Fascia Grille Replacement > Page 14949
Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Support Replacement
Front Bumper Fascia Support Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Fascia Grille Replacement > Page 14950
Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Air Deflector Replacement
Front Bumper Fascia Air Deflector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair
Front Bumper Reinforcement: Service and Repair
Front Bumper Impact Bar Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System
Information > Service and Repair
Front Bumper Shock Absorber: Service and Repair
Front Bumper Fascia Energy Absorber Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting
Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to
Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System
Information > Service and Repair > Rear Bumper Fascia Center Grille Replacement (Equinox SS)
Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Center Grille Replacement
(Equinox SS)
Rear Bumper Fascia Center Grille Replacement (Equinox SS)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System
Information > Service and Repair > Rear Bumper Fascia Center Grille Replacement (Equinox SS) > Page 14964
Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Replacement
Rear Bumper Fascia Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System
Information > Service and Repair > Rear Bumper Fascia Center Grille Replacement (Equinox SS) > Page 14965
Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Reflector Replacement
Rear Bumper Fascia Reflector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System
Information > Service and Repair
Rear Bumper Reinforcement: Service and Repair
Rear Bumper Impact Bar Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Shock Absorber > System
Information > Service and Repair
Rear Bumper Shock Absorber: Service and Repair
Rear Energy Absorber Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
Front Side Door Outside Handle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Interior Handle > System Information > Service and Repair > Door Handle Bezel Replacement (Front Side Door)
Front Door Interior Handle: Service and Repair Door Handle Bezel Replacement (Front Side Door)
Door Handle Bezel Replacement (Front Side Door)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Interior Handle > System Information > Service and Repair > Door Handle Bezel Replacement (Front Side Door)
> Page 14983
Front Door Interior Handle: Service and Repair Door Inside Handle Replacement
Door Inside Handle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle >
Front Door Interior Handle > System Information > Service and Repair > Door Handle Bezel Replacement (Front Side Door)
> Page 14984
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair
Front Door Hinge: Service and Repair
Front Side Door Hinge Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge >
System Information > Service and Repair > Page 14988
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch >
System Information > Diagrams
Front Door Latch: Diagrams
Component Connector End Views
Door Latch - Driver
Door Latch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch >
System Information > Diagrams > Page 14992
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch >
System Information > Diagrams > Page 14993
Front Door Latch: Service and Repair
Front Side Door Latch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch >
System Information > Diagrams > Page 14994
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter >
System Information > Service and Repair
Front Door Limiter: Service and Repair
Front Side Door Check Link Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement
Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement
Front Side Door Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 15002
Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement
Front Side Door Water Deflector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel >
System Information > Service and Repair > Front Side Door Trim Panel Replacement > Page 15003
Front Door Panel: Service and Repair Upper Extension Trim Panel Replacement (Front Side Door)
Upper Extension Trim Panel Replacement (Front Side Door)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments > Front Side Door Lock Striker Adjustment
Front Door Striker: Adjustments Front Side Door Lock Striker Adjustment
Front Side Door Lock Striker Adjustment
To determine if striker adjustment is required, proceed as follows:
Caution: In order to prevent SIR deployment, personal injury, or unnecessary SIR system repairs,
do not strike the door or the door pillar in the area of the side impact sensor (SIS). Turn OFF the
ignition and remove the key when performing service in the area of the SIS.
1. Ensure the door is properly aligned within the door opening before proceeding with the striker
adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the
door to move upward or downward upon contact with the
striker. Also note the closing effort to fully engage the latch.
3. Using a grease pencil, mark around the striker for reference of the original position. Loosen the
striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper
door position within the door opening. Start with the
up/down position, then position the striker to achieve proper alignment to the door opening. Set the
in/out adjustment for the proper door seal engagement making sure the door closing efforts are
correct.
Notice: Refer to Fastener Notice.
5. Tighten the striker bolts.
Tighten the door striker bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments > Front Side Door Lock Striker Adjustment > Page 15008
Front Door Striker: Adjustments Lock Striker Adjustment
Lock Striker Adjustment
Important: Make certain the liftgate is properly aligned within the liftgate opening before proceeding
with the striker adjustment.
1. Close the liftgate onto the striker and note if liftgate drags on striker causing the liftgate to move
side to side upon contact with the striker. Also
note closing efforts to fully engage latch.
2. Mark around the striker with a grease pencil for reference of original position. 3. Loosen striker
bolts. 4. Move the striker to eliminate drag on striker and liftgate latch and to achieve proper liftgate
position within the liftgate opening. 5. Align the left/right liftgate position, then position the striker to
achieve proper alignment to liftgate opening. 6. Align the in/out adjustment for proper liftgate seal
engagement making sure the liftgate closing efforts are correct.
Notice: Refer to Fastener Notice.
7. Verify correct alignment of striker and tighten striker bolts.
Tighten the bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker >
System Information > Adjustments > Page 15009
Front Door Striker: Service and Repair
Front Side Door Lock Striker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip
> Component Information > Service and Repair
Front Door Weatherstrip: Service and Repair
Front Door Opening Weatherstrip Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 15017
Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information
INFORMATION
Bulletin No.: 06-08-64-001B
Date: October 20, 2009
Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock
Box
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add vehicles and model years and to include all types of
door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body &
Accessories).
- In several warranty parts review cases, side door window glass was observed with a chip or chips
on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box
on the front side door window glass.
- A random selection of side door glass returns will be conducted to confirm adherence. If a side
door glass is discovered with a chip or chips in the location previously described, the side door
glass will be returned to the dealership for debit.
Example of Side Door Glass
- DO NOT place a vehicle key lock box on a side door window glass.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Glass > System Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 15018
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Motor > Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Front Side Door Window Regulator Motor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
Front Side Door Window Regulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle >
Rear Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
Rear Side Door Outside Handle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge >
System Information > Service and Repair
Rear Door Hinge: Service and Repair
Rear Side Door Hinge Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Diagrams
Rear Door Latch: Diagrams
Component Connector End Views
Door Latch - Driver
Door Latch - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Diagrams > Page 15036
Door Latch - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Diagrams > Page 15037
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Diagrams > Page 15038
Rear Door Latch: Service and Repair
Rear Side Door Latch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch >
System Information > Diagrams > Page 15039
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair
Rear Door Limiter: Service and Repair
Rear Side Door Check Link Replacement
Removal Procedure
Caution: In order to prevent SIR deployment, personal injury, or unnecessary SIR system repairs,
do not strike the door or the door pillar in the area of the side impact sensor (SIS). Turn OFF the
ignition and remove the key when performing service in the area of the SIS.
1. Remove the rear door trim panel. 2. Remove the rear door lower speaker. 3. Remove the check
link bolts at the hinge pillar.
4. Remove the check link nuts from the door frame. 5. Remove the check link from the door
through the speaker opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter >
System Information > Service and Repair > Page 15043
Installation Procedure
1. Install the check link to the door frame.
Notice: Refer to Fastener Notice.
2. Install the nuts to the check link.
Tighten the nuts to 10 N.m (89 lb in).
3. Install the check link bolts.
Tighten the bolts to 10 N.m (89 lb in).
4. Install the rear door lower speaker. 5. Install the rear door trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Door Handle Bezel Replacement (Rear Side Door)
Rear Door Panel: Service and Repair Door Handle Bezel Replacement (Rear Side Door)
Door Handle Bezel Replacement (Rear Side Door)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Door Handle Bezel Replacement (Rear Side Door) > Page 15048
Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement
Rear Side Door Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Door Handle Bezel Replacement (Rear Side Door) > Page 15049
Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement
Rear Side Door Water Deflector Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel >
System Information > Service and Repair > Door Handle Bezel Replacement (Rear Side Door) > Page 15050
Rear Door Panel: Service and Repair Upper Extension Trim Panel Replacement (Rear Side Door)
Upper Extension Trim Panel Replacement (Rear Side Door)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Adjustments
Rear Door Striker: Adjustments
Rear Side Door Lock Striker Adjustment
To determine if striker adjustment is required, proceed as follows:
Caution: In order to prevent SIR deployment, personal injury, or unnecessary SIR system repairs,
do not strike the door or the door pillar in the area of the side impact sensor (SIS). Turn OFF the
ignition and remove the key when performing service in the area of the SIS.
1. Ensure the door is properly aligned within the door opening before proceeding with the striker
adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the
door to move upward or downward upon contact with the
striker. Also note the closing effort to fully engage the latch.
3. Using a grease pencil, mark around the striker for reference of the original position. Loosen the
striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper
door position within the door opening. Start with the
up/down position, then position the striker to achieve proper alignment to the door opening. Set the
in/out adjustment for the proper door seal engagement making sure the door closing efforts are
correct.
Notice: Refer to Fastener Notice.
5. Tighten the striker bolts.
Tighten the door striker bolts to 25 N.m (18 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker >
System Information > Adjustments > Page 15054
Rear Door Striker: Service and Repair
Rear Side Door Lock Striker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip
> Component Information > Service and Repair
Rear Door Weatherstrip: Service and Repair
Rear Door Opening Weatherstrip Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Motor > Component Information > Service and Repair
Rear Door Window Motor: Service and Repair
Rear Side Door Window Regulator Motor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window
Regulator > System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Rear Side Door Window Regulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service
and Repair
Fuel Door: Service and Repair
Fuel Tank Filler Door Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information
> Service and Repair
Hood Hinge: Service and Repair
Hood Hinge Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component
Information > Service and Repair
Hood Insulator / Pad: Service and Repair
Hood Insulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Service and Repair > Hood Primary and Secondary Latch Replacement
Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement
Hood Primary and Secondary Latch Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information
> Service and Repair > Hood Primary and Secondary Latch Replacement > Page 15078
Hood Latch: Service and Repair Hood Secondary Latch Replacement
Hood Secondary Latch Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair
Hood Latch Release Cable: Service and Repair
Hood Primary Latch Release Cable Replacement
Removal Procedure
1. Open the hood. 2. Remove the hood latch.
3. Remove the hood primary latch release cable from the structure. Note the routing of the hood
cable in the engine compartment for installation.
4. Inside the vehicle, remove the left front carpet retainer. Refer to Front Carpet Retainer
Replacement. 5. Reposition the carpet aside to expose release handle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair > Page 15082
6. Pull release handle to up position. 7. Pry back front of handle slip to disengage from the hinge
pillar. 8. Remove the hood primary latch release cable grommet from the front of the dash and
remove the cable from the core support.
Installation Procedure
1. Install the hood primary latch release cable and grommet through the front of the dash. 2. Slide
the hood release handle into the hinge pillar and secure into place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable >
Component Information > Service and Repair > Page 15083
3. Reposition the carpet and install the front carpet retainer.Refer to Front Carpet Retainer
Replacement.
4. Route the hood cable through the body structure. 5. Install the hood latch. 6. Inspect the hood
primary latch release cable for proper operation. 7. Close the hood.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component
Information > Service and Repair > Hood Hold-Open Rod Replacement
Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement
Hood Hold-Open Rod Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component
Information > Service and Repair > Hood Hold-Open Rod Replacement > Page 15088
Hood Shock / Support: Service and Repair Hood Strut Replacement
Hood Strut Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component
Information > Service and Repair > Hood Rear Outer Seal Replacement
Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement
Hood Rear Outer Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component
Information > Service and Repair > Hood Rear Outer Seal Replacement > Page 15097
Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement
Hood Rear Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Service and Repair
Trunk / Liftgate Hinge: Service and Repair
Liftgate Hinge Replacement
Removal Procedure
Caution: When a lift gate hold open device is being removed or installed, provide alternate support
to avoid the possibility of damage to the vehicle or personal injury.
1. Open the liftgate and support. 2. Remove the liftgate trim panel. 3. Mark the location of the
liftgate hinges with a grease pencil. 4. Remove the liftgate struts. 5. Remove the hinge to liftgate
bolts. 6. Remove the hinge to body nuts. 7. Remove the hinges one at a time.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Service and Repair > Page 15102
Important: New hinge to body nuts must be used to ensure a proper seal.
1. Align the hinge to body alignments marks made in the removal process and install the nuts. 2.
Align the hinge to liftgate alignment marks made in the removal process and install the bolts. 3.
Install the liftgate struts. 4. Lower the liftgate slowly and inspect the alignment. Align as needed.
Notice: Refer to Fastener Notice.
5. Tighten the nuts to the liftgate hinges.
Tighten the hinge to body nuts to 25 N.m (18 lb ft).
6. Tighten the hinge to liftgate bolts.
Tighten the hinge to liftgate bolts to 25 N.m (18 lb ft).
7. Install the liftgate trim panel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair
Trunk / Liftgate Handle: Service and Repair
Liftgate Outside Handle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair
Trunk / Liftgate Interior Trim Panel: Service and Repair
Liftgate Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Diagrams
Trunk / Liftgate Latch: Diagrams
Component Connector End Views - Continued
Liftgate Latch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay >
Component Information > Locations
Trunk / Liftgate Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock /
Support > Component Information > Service and Repair
Trunk / Liftgate Shock / Support: Service and Repair
Liftgate Strut Replacement
Removal Procedure
Caution: When a lift gate hold open device is being removed or installed, provide alternate support
to avoid the possibility of damage to the vehicle or personal injury.
1. Open and support the liftgate.
Important: Spring clips should not be removed from the struts.
2. Lift up and partially remove the spring clips on the strut using a small flat-bladed tool.
3. Remove the upper end of the strut from the ball joint.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock /
Support > Component Information > Service and Repair > Page 15118
4. Remove the lower end of the strut from the ball joint. 5. Remove the strut from the liftgate.
Installation Procedure
1. Position the strut to the liftgate.
2. Install the upper end of the strut to the ball joint. Press in to place until fully seated.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock /
Support > Component Information > Service and Repair > Page 15119
3. Install the lower end of the strut to the ball joint. Press in to place until fully seated. 4. Remove
the support from the liftgate. 5. Close the liftgate.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker >
Component Information > Service and Repair
Trunk / Liftgate Striker: Service and Repair
Liftgate Lock Striker Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams
Trunk / Liftgate Switch: Diagrams
Component Connector End Views - Continued
Liftgate Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide
Trunk / Liftgate Weatherstrip: Customer Interest Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15134
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15135
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15136
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15137
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15138
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide
Trunk / Liftgate Weatherstrip: All Technical Service Bulletins Body - General Water Leak Diagnostic
Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15144
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15145
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15146
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15147
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
08-08-57-001A > Oct > 08 > Body - General Water Leak Diagnostic Guide > Page 15148
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip
> Component Information > Technical Service Bulletins > Page 15149
Trunk / Liftgate Weatherstrip: Service and Repair
Liftgate Wedge Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION
Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION
NOTIFICATION
TECHNICAL
Bulletin No.: 06-08-111-004B
Date: September 25, 2009
Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems
Including Chevy Bowtie (Bulletin Cancelled)
Models:
2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2
2006-2009 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number
06-08-111-004A (Section 08 - Body & Accessories).
This bulletin is being cancelled. The information is no longer applicable.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Front Side Door Emblem/Nameplate Replacement (AWD)
Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (AWD)
Front Side Door Emblem/Nameplate Replacement (AWD)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Front Side Door Emblem/Nameplate Replacement (AWD) > Page 15157
Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (GM)
Front Side Door Emblem/Nameplate Replacement (GM)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Front Side Door Emblem/Nameplate Replacement (AWD) > Page 15158
Body Emblem: Service and Repair Liftgate Emblem/Nameplate Replacement (Equinox)
Liftgate Emblem/Nameplate Replacement (Equinox)
Removal Procedure
1. When replacing an emblem/nameplate do the following:
1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for
installation of the emblem/nameplate.
2. To remove an emblem/nameplate, heat the emblem/nameplate using a heat gun. 3. Apply the
heat using a circular motion for about 30 seconds holding the heat gun approximately 152 mm (6
in) from the surface.
Notice: Refer to Exterior Trim Emblem Removal Notice.
4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When
replacing, remove all adhesive as follows:
* For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501
or equivalent.
* For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a
50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive.
Installation Procedure
Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that
could come into contact with the sticky backing. Foreign material may cause improper adhesion.
1. Clean the area where the emblem/nameplate will be installed.
Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume
of isopropyl alcohol and water to clean the area.
2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply
tape and mark the location as shown below.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Front Side Door Emblem/Nameplate Replacement (AWD) > Page 15159
4. For the EQUINOX emblem/nameplate install to the following dimensions:
Important: All dimensions are arc length measurements.
* Dimension (a) is 11 mm (0.043 in) from the side of the emblem/nameplate to the left edge of the
lift gate.
* Dimension (b) is 160 mm (6.30 in) from the center of the emblem/nameplate to the bottom of the
lift gate.
5. For the CHEVROLET emblem/nameplate install to the following dimensions:
Important: All dimensions are arc length measurements.
* Dimension (a) is 31 mm (1.22 in) from the side of the emblem/nameplate to the right edge of the
lift gate.
* Dimension (b) is 160 mm (6.30 in) from the center of the emblem/nameplate to the bottom of the
lift gate.
6. Heat the mounting surface to approximately 27-41°C (80-105°F) using the heat gun, if
necessary. 7. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C
(85-90°F).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information >
Service and Repair > Front Side Door Emblem/Nameplate Replacement (AWD) > Page 15160
Important: Do not touch the adhesive backing on the emblem/nameplate.
8. Remove the protective liner from the back of the emblem/nameplate. 9. Position the
emblem/nameplate to the location marks and press the emblem/nameplate to the mounting
surface.
10. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting
surface. 11. Remove the protective tape from the mounting surface.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component
Information > Service and Repair
License Plate Bracket: Service and Repair
Rear License Plate Pocket Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component
Information > Service and Repair
Windshield Moulding / Trim: Service and Repair
Windshield Frame Applique Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information >
Service and Repair
Front Fender Liner: Service and Repair
Front Wheelhouse Liner Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information >
Service and Repair
Rear Fender Liner: Service and Repair
Rear Wheelhouse Liner Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Firewall > Component Information > Service and Repair
Firewall: Service and Repair
Plenum Upper Panel Replacement
Removal Procedure
Caution: Refer to Approved Equipment for Collision Repair Caution.
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. 3. Remove all related panels and components. 4. Repair
as much of the damage as possible to factory specifications. 5. Note the location and remove the
sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion
Treatment and
Repair.
Important: Do not damage any inner panels or reinforcements.
6. Locate and drill out all factory welds. Note the number and location of the welds for installation of
the plenum top panel. 7. Remove the damaged plenum top panel.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Firewall > Component Information > Service and Repair > Page 15179
Important: If the location of the original plug weld holes can not be determined, space the plug weld
holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru
adhesive with an additional spot weld between each factory spot weld.
1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from
the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru
Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair. 4.
Position the plenum top panel to the vehicle using 3-dimensional measuring equipment. Clamp the
plenum top panel into place. 5. Plug weld accordingly. 6. Clean and prepare all welded surfaces. 7.
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair. 8. Paint the repair area. Refer to Basecoat/Clearcoat Paint
Systems. 9. Install all related panels and components.
10. Connect the negative battery cable. 11. Enable the SIR system. Refer to SIR Disabling and
Enabling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Service and Repair
Body / Frame Mount Bushing: Service and Repair
Frame Cushion or Insulator Replacement
Special Tools
CH-47672 Frame Insulator Remover/Installer
Removal Procedure
1. Remove the frame from the vehicle.
2. Remove the upper frame insulator (1)
3. Assemble the CH-47672 press as shown, on the frame insulator being removed.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Service and Repair > Page 15184
4. Use the CH-47672 press to remove the frame insulator from the frame.
Installation Procedure
1. Clean the frame insulator opening. 2. Apply thin coat of rubber lubricant GM P/N 1051717
(Canadian P/N 5728223), or equivalent to the inside of the frame insulator opening and to
the insulator.
3. Install the CH-47672 clamp to the bushing. Align the clamp screws with the split portion of the
bushing. Position the edge of the clamp where the
bushing chamfer blends with the straight section of the bushing. Alternately tighten the clamp
screws until the split edges of the bushing are parallel and almost touching.
Important: The frame insulator splits must be aligned in a forward and rearward position relative to
the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Service and Repair > Page 15185
4. Install the frame insulator to the front frame opening with the insulator splits aligned in a forward
and rearward direction relative to the vehicle.
5. Assemble the CH-47672 clamp and the frame insulator as shown to the frame.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Service and Repair > Page 15186
6. Use the CH-47672 press to begin installing the frame insulator into the frame. STOP and remove
the CH-47672 clamp (1) before the clamp
becomes trapped between the CH-47672 press and frame.
7. Use the CH-47672 press to finish installing the frame insulator into the frame.
Important: Inspect and confirm that there is NO visible gap between the insulator and the frame.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Service and Repair > Page 15187
8. Remove the CH-47672 from the insulator and frame. Inspect and confirm that the insulator (2) is
in direct contact with the frame (1).
9. Install the upper frame insulator (1)
10. Install the frame to the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair
Cross-Member: Service and Repair
Drivetrain and Front Suspension Frame Reinforcement Replacement (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair
Front Subframe: Service and Repair
Frame Replacement (LNJ)
Tools Required
* J 43828 Ball Joint Remover
* SA9140E Torque Angle Gage
Removal Procedure
1. Secure the radiator to the upper radiator support. 2. Raise and support the vehicle. refer to
Vehicle Lifting. 3. Remove the front wheels. 4. Remove the side splash shield-to-frame fasteners.
5. Remove the front air dam-to-frame fasteners.
6. Remove the rear transaxle mount-to-frame bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair > Page 15195
7. Remove the front transaxle mount through bolt.
8. Remove the steering gear-to-frame bolts. 9. Using mechanics wire, secure the steering gear to
the exhaust.
10. Remove the stabilizer shaft clamp-to-frame bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair > Page 15196
11. Remove the lower ball joint cotter pins. Discard the cotter pins.
12. Loosen the lower ball joint castle nut until the nut is level with the top of the ball stud.
Notice: Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or
bushing may result.
13. Using the J 43828, separate the lower control arm from the steering knuckle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair > Page 15197
14. Remove the frame-to-body bolts. Discard the bolts. 15. Carefully lower the frame from the
vehicle. 16. Remove the lower control arms.
Installation Procedure
1. Install the lower control arms. 2. Raise the frame to the body.
Important: Do not tighten the fasteners at this time.
3. Loosely install new frame-to-body bolts.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair > Page 15198
4. Connect the ball joint stud to the steering knuckle.
Notice: Refer to Fastener Notice.
5. Install the ball stud castle nut.
Tighten the nut to 40 N.m (30 lb in).
Important:
* Do not loosen the castle nut in order to align the cotter pin slots.
* Ensure the cutter pin ends do not contact the wheel speed sensor harness.
Continue to tighten the castle nut to align the slots with the opening in the ball stud and install the
ball stud cotter pin.
7. Remove the mechanics wire and install the steering gear to the frame.
Tighten the bolts to 110 N.m (81 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service
and Repair > Page 15199
8. Install the front transaxle mount through bolt.
Tighten the bolt to 110 N.m (81 lb ft).
9. Install the rear transaxle mount-to-frame bolts.
Tighten the bolts to 50 N.m (37 lb ft).
10. Install the stabilizer shaft clamp.
Tighten the bolts to 50 N.m (37 lb ft).
11. Tighten the frame-to-body bolts.
Tighten the bolts to 155 N.m (114 lb ft).
12. Install the front air dam fasteners. 13. Install the side splash shield-to-frame fasteners. 14.
Install the front wheels. 15. Lower the vehicle. 16. Release the radiator from the upper radiator
support. 17. Align the front suspension. Refer to Front Toe Adjustment.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair
Grille: Service and Repair
Fascia Grille Replacement
Removal Procedure
1. Remove the front fascia assembly (3). 2. Remove the front fascia support. 3. Remove the
radiator grille strap (2) from the back of the grille by depressing the grille strap fingers and pushing
through the front of the grille.
4. Remove the screw from the bottom center of the grille. 5. Remove the grille from the front fascia
by releasing the retainers around the perimeter of the grille.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 15203
1. Position the grille to the front fascia. 2. Install the grille to the front fascia by pushing in to secure
the retainers around the perimeter of the grille.
Notice: Refer to Fastener Notice.
3. Install the screw to the bottom center of the grille.
Tighten the screw to 2 N.m (18 lb in).
4. Install the radiator grille strap into the front fascia and grille by pushing the fingers on the strap
into the grille and fascia until fully secured. 5. Install the front fascia support. 6. Install the front
fascia assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle
Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle
INFORMATION
Bulletin No.: 06-00-89-029F
Date: April 27, 2010
Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather,
Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability
Models:
2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum
and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009
Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-00-89-029E (Section 00 - General Information).
To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the
upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which
can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care
should be taken because newspapers and garments may transfer color to the vehicle's interior.
Many of today's interiors are made with new low gloss materials. Permanent damage may result
from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and
fabric) for which they are not intended. Using non-approved products can actually set the stain to
the point that nothing can remove it.
Important
Do not use silicone or wax-based products or those containing organic solvents (such as naptha,
alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing
the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the
windshield and even make it difficult to see through the windshield under certain conditions.
- Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This
can cause damage to the vehicle's interior surfaces.
- Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt.
Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of
the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are
in the neutral-pH range and will maintain the best vehicle interior appearance. These products are
water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals.
Interior trim pieces on new vehicles, as well as service components, arrive with a protective film.
When removing the protective film, adhesive residue may be left on the trim panels/components.
The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing
adhesive residue without causing damage to the component.
Important
- If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the
residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the
pH neutral range, they won't leave behind soapy residue.
- On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be
treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this
bulletin for more information.
Effective cleaning steps for hard and/or plastic surfaces:
1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the
towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work
cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the
surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the
towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's
original luster.
Important Today's interiors are developed and intended to have a low-gloss appearance. It is
important to use only products which provide a low-gloss finish in order to maintain the interior's
integrity, customer appeal and satisfaction.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15209
Effective cleaning steps for fabric:
1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate
stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle
brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to
reduce or eliminate future staining.
Upholstery and Carpet Stains
When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you
determine which cleaner/formula works best on a particular stain. The chart lists many of the
common stains. Some complex stains may require the application of both stain removers, one after
the other, to remove both food-based oils and synthetic oils.
A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain
or material. This enables the dirt/stain to be completely removed from the material.
Leather Conditioner/Restorer
A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a
water-based product and contains essential emollients to restore suppleness, conditions and adds
luster without adding gloss. The restorer will also provide protection against re-staining.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15210
Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede
comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will
appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely
affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with
the restorer.
Extractor Machine and Concentrate
For difficult to clean materials or when cleaning a large area, the best results will be achieved when
using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N
627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released
a concentrate for use with the extractor machine.
Whichever extractor machine is used, it should meet the minimum specifications of the Ruby
Extractor:
Ruby Extractor Specifications:
- Pump PSI: 55
- Water Lift: 85"
- Hose Length: 10 ft
Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty.
Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in
the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The
water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry
time is greatly reduced due to less water on the fabric surface, the vacuum head making better
contact with the surface and the significant water lift capability of the machine.
Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help
remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions
listed on the container. The available concentrate helps to break the stain down and then the stain
is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to
remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions.
Dirt, grease and grime are more easily removed when the proper solution is used during the
extraction process.
Parts Information
Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles.
Available Equipment
Equipment is available by contacting 1-800-GMTOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15211
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15212
Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats
INFORMATION
Bulletin No.: 10-08-110-001
Date: March 30, 2010
Subject: Information on Proper Use of Floor Mats
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2
2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X
GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM
vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly
may cause interference with the accelerator or brake pedal. Please review the following safety
guidelines regarding proper driver's side floor mat usage with the customer.
Warning
If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal
and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or
increased stopping distance which can cause a crash and injury. Make sure the floor mat does not
interfere with the accelerator or brake pedal.
- Do not flip the driver's floor mat over (in an effort to keep the floor mat clean)
- Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel)
- Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber
mats over carpeted floor mats)
- Only use floor mats that are designed specifically for your vehicle
- When using replacement mats, make certain the mats do not interfere with the accelerator or
brake pedal before driving the vehicle
If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is
installed correctly and according to the instructions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15213
After installing floor mats, make certain they cannot move and do not interfere with the accelerator
or brake pedals.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15214
Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors
INFORMATION
Bulletin No.: 00-00-89-027E
Date: September 29, 2008
Subject: Eliminating Unwanted Odors in Vehicles
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add model years and refine the instructions. Please discard
Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information).
Vehicle Odor Elimination
General Motors offers a product that may control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic,
biodegradable odor remover. This odorless product has been shown to greatly reduce or remove
objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer
created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl,
leather, carpet and sound deadening materials. It may also be induced into HVAC modules and
instrument panel ducts (for the control of non-bacterial related odors).
Important:
This product leaves no residual scent and should not be sold as or considered an air freshener.
Product action may result in the permanent elimination of an odor and may be preferable to
customers with allergies who are sensitive to perfumes.
How to Use This Product
GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam
cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all
vehicle interiors. Do not wet or soak any interior surface that plain water would cause to
deteriorate, as this product will have the same effect. Also avoid letting this product come into
contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of,
or render GM Vehicle Care Odor Eliminator inert.
Note:
Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a
replacement set faxed or e-mailed to your dealership.
Instructions and cautions are printed on the bottle, but additional help is available. If you encounter
a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada,
1-800-977-4145) to obtain additional information and usage suggestions.
Important:
This product may effectively remove odors when directly contacting the odor source. It should be
used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the
root cause of the odor, and then the residual odor to permanently correct the vehicle condition.
Vehicle Waterleak Odor Elimination
STEP ONE:
Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water
soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor
source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle
interior by careful evaluation. Odor evaluation may need to be performed by multiple persons.
Another method of isolating an odor source is to remove and segregate interior trim and
components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist
in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated
separately to determine if the odor stays with the vehicle or the interior components. Odors that
stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak
at the windshield or standing water in the front foot well area caused mold/mildew to form on the
bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and
primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and
dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product
before reinstalling carpet or reassembling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15215
The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used
properly. It must come into direct contact with the odor source. It should be used in conjunction with
diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after
odor root cause correction are:
STEP TWO:
^ Use the trigger spray head.
^ Put a drop of dish soap the size of a quarter in the bottom of a bottle.
^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with
tap water.
^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan)
STEP THREE:
The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and
upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting
(at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The
headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and
upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should
be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface.
STEP FOUR: (vehicle ventilation system treatment)
The ventilation system is generally the last step in the treatment of the vehicle.
a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per
vent).
b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting).
c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of
windshield)
d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents.
e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into
the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell
coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray
3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7
minutes.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited
is resolved without completing every step, the remaining steps do not need to be performed. If
these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.
Additional Suggestions to Increase Customer Satisfaction
Here are some additional ideas to benefit your dealership and to generate greater customer
enthusiasm for this product.
^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to
your used car trades; treat loaner and demo cars during service and at final sale to eliminate
smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of
your normal vehicle detailing service.
^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle
purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM
Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the
vehicle. Customers may find this product can be used for a host of recreational activities
associated with their new vehicle, such as deodorizing a boat they tow, or a camper.
^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase
dealership traffic as these superior quality products cannot be purchased in stores. Many
Dealerships have product displays at the parts counter. Consider additional displays in the
Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many
customers who purchase vehicles and receive regular maintenance at your dealership may never
visit the parts counter, and subsequently are not exposed to the variety and value that these
products offer.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15216
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles
Carpet: Service and Repair Eliminating Unwanted Odors in Vehicles
Eliminating Unwanted Odors in Vehicles
GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or
eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic,
biodegradable, odorless product has been shown to greatly reduce or remove the following types
of odor:
* Objectionable smells of mold and mildew resulting from vehicle water leaks
* Customer created odors, such as smoke
You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound
deadening materials. You may also induce this product into HVAC modules and instrument panel
ducts for the control of non-bacterial related odors.
Important: This product leaves no residual scent and should not be used as an air freshener.
This product may result in the permanent elimination of an odor and may be preferable to
customers whose allergies make them sensitive to perfumes. This product may effectively remove
odors when directly contacting the odor source. In cases such as water leaks, use this product with
diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications
on the residual odor to permanently correct the vehicle condition.
How to Use this Product
* Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam
cleaners.
* Do not use on any interior surface that plain water would deteriorate, because this product will
have the same effect. Also avoid letting this product come into contact with vinegar or any acidic
substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator.
* Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost contact to get a replacement set faxed or
e-mailed to your dealership.
* Instructions and cautions are printed on the bottle, but additional help is available. If you
encounter a persistent or recurring odor, you may call to obtain additional information and usage
suggestions.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15219
Carpet: Service and Repair Floor Carpet Drying
Floor Carpet Drying
If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the
components:
* For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly.
* For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While
the carpet is out of the vehicle, dry the carpet using the method described below.
* For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry
the carpet using the method described below.
* For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method
described below.
Drying Method
1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess
moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as
possible. 3. Point a fan at the affected area and air dry the carpet.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15220
Carpet: Service and Repair Floor Panel Carpet Replacement
Floor Panel Carpet Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15221
Carpet: Service and Repair Front Carpet Retainer Replacement
Front Carpet Retainer Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15222
Carpet: Service and Repair
Eliminating Unwanted Odors in Vehicles
Eliminating Unwanted Odors in Vehicles
GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or
eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic,
biodegradable, odorless product has been shown to greatly reduce or remove the following types
of odor:
* Objectionable smells of mold and mildew resulting from vehicle water leaks
* Customer created odors, such as smoke
You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound
deadening materials. You may also induce this product into HVAC modules and instrument panel
ducts for the control of non-bacterial related odors.
Important: This product leaves no residual scent and should not be used as an air freshener.
This product may result in the permanent elimination of an odor and may be preferable to
customers whose allergies make them sensitive to perfumes. This product may effectively remove
odors when directly contacting the odor source. In cases such as water leaks, use this product with
diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications
on the residual odor to permanently correct the vehicle condition.
How to Use this Product
* Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam
cleaners.
* Do not use on any interior surface that plain water would deteriorate, because this product will
have the same effect. Also avoid letting this product come into contact with vinegar or any acidic
substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator.
* Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost contact to get a replacement set faxed or
e-mailed to your dealership.
* Instructions and cautions are printed on the bottle, but additional help is available. If you
encounter a persistent or recurring odor, you may call to obtain additional information and usage
suggestions.
Floor Carpet Drying
Floor Carpet Drying
If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the
components:
* For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly.
* For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While
the carpet is out of the vehicle, dry the carpet using the method described below.
* For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry
the carpet using the method described below.
* For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method
described below.
Drying Method
1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess
moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as
possible. 3. Point a fan at the affected area and air dry the carpet.
Floor Panel Carpet Replacement
Floor Panel Carpet Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15223
Front Carpet Retainer Replacement
Front Carpet Retainer Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15224
Rear Carpet Retainer Replacement
Rear Carpet Retainer Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15225
Rear Seat Floor Filler Trim Panel Mounting Rod Replacement
Rear Seat Floor Filler Trim Panel Mounting Rod Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15226
1. Fold down the rear seat to expose the rear seat floor filler trim panel
2. Lift the filler trim panel. Pull the the filler trim panel to remove from the mounting rod
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15227
3. Use a small tool to release the mounting rod from the rear seat.
Installation Procedure
1. Push the rod into the guide until locked.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service
and Repair > Eliminating Unwanted Odors in Vehicles > Page 15228
2. Install the filler trim panel to the rod.
3. Raise the seat back to the upright position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information >
Specifications
Console: Specifications
Fastener Tightening Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement
Console: Service and Repair Console Replacement
Console Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15234
Console: Service and Repair Console Trim Plate Replacement
Console Trim Plate Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15235
Console: Service and Repair Front Floor Console Armrest Replacement
Front Floor Console Armrest Replacement
Removal Procedure
1. Move the front seats rearward and open the center armrest cover.
2. Remove the screws from the hinge holding the armrest cover to the center console. 3. Remove
the armrest cover.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15236
1. Align the armrest cover with the hinge positioned correctly.
Notice: Refer to Fastener Notice.
2. Install the screws to the hinge holding the armrest cover to the center console.
Tighten the screws to 2 N.m (18 lb in).
3. Close the armrest cover. Inspect the cover for proper alignment and operation. 4. Return the
front seat to the proper position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15237
Console: Service and Repair Front Floor Console Compartment Door Latch Replacement
Front Floor Console Compartment Door Latch Replacement
Removal Procedure
1. Lift the armrest cover to expose the armrest hinge and insert.
2. Remove the screws from the armrest cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15238
3. Remove the console latch cover to expose the latch screws.
4. Remove the latch screws from the center console armrest cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15239
5. Remove the latch from the armrest cover.
Installation Procedure
1. Align the new latch to the armrest cover.
Notice: Refer to Fastener Notice.
2. Install the latch screws to the armrest cover.
Tighten the screws to 2.5 N.m (22 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15240
3. Install the screws that secure the armrest cover to the center console.
Tighten the screws to 2.5 N.m (22 lb in).
4. Snap the console insert to the armrest cover. 5. Close the armrest cover. Inspect the cover for
alignment and operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15241
Console: Service and Repair
Console Replacement
Console Replacement
Console Trim Plate Replacement
Console Trim Plate Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15242
Front Floor Console Armrest Replacement
Front Floor Console Armrest Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15243
1. Move the front seats rearward and open the center armrest cover.
2. Remove the screws from the hinge holding the armrest cover to the center console. 3. Remove
the armrest cover.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15244
1. Align the armrest cover with the hinge positioned correctly.
Notice: Refer to Fastener Notice.
2. Install the screws to the hinge holding the armrest cover to the center console.
Tighten the screws to 2 N.m (18 lb in).
3. Close the armrest cover. Inspect the cover for proper alignment and operation. 4. Return the
front seat to the proper position.
Front Floor Console Compartment Door Latch Replacement
Front Floor Console Compartment Door Latch Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15245
1. Lift the armrest cover to expose the armrest hinge and insert.
2. Remove the screws from the armrest cover.
3. Remove the console latch cover to expose the latch screws.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15246
4. Remove the latch screws from the center console armrest cover.
5. Remove the latch from the armrest cover.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15247
1. Align the new latch to the armrest cover.
Notice: Refer to Fastener Notice.
2. Install the latch screws to the armrest cover.
Tighten the screws to 2.5 N.m (22 lb in).
3. Install the screws that secure the armrest cover to the center console.
Tighten the screws to 2.5 N.m (22 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15248
4. Snap the console insert to the armrest cover. 5. Close the armrest cover. Inspect the cover for
alignment and operation.
Front Floor Console Compartment Replacement
Front Floor Console Compartment Replacement
Removal Procedure
1. Raise the console lid to expose the hinge.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15249
2. Remove the screws that retain the console hinge to the base. Remove the console hinge. 3.
Remove the console storage bin.
Installation Procedure
1. Insert the new storage bin.
Notice: Refer to Fastener Notice.
2. Fasten the storage bin cover with the hinge screws.
Tighten the screws to 2 N.m (18 lb in).
3. Inspect the lid for alignment and operation.
Front Floor Console Rear Cover Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15250
Front Floor Console Rear Cover Replacement
Front Floor Console Side Trim Panel Replacement - Left Side
Front Floor Console Side Trim Panel Replacement - Left Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15251
Front Floor Console Side Trim Panel Replacement - Right Side
Front Floor Console Side Trim Panel Replacement - Right Side
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15252
Roof Console Replacement
Roof Console Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service
and Repair > Console Replacement > Page 15253
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Page 15258
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Front Floor Console Front Cup Holder Replacement
Drink Holders: Service and Repair Front Floor Console Front Cup Holder Replacement
Front Floor Console Front Cup Holder Replacement
Removal Procedure
1. Open the arm rest on the console. 2. Remove the cupholder cover. 3. Remove the screws from
the cup holder track. 4. Remove the cup holder and the track from the console.
5. Pull to separate the cup holder from the track.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Front Floor Console Front Cup Holder Replacement > Page 15263
1. Install the cup holder to the track. 2. Position the track in the console assembly.
Notice: Refer to Fastener Notice.
3. Install the console track screws.
Tighten the screw to 2.5 N.m (22 lb in).
4. Snap the cupholder cover in place. 5. Inspect the cupholder for correct operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Front Floor Console Front Cup Holder Replacement > Page 15264
Drink Holders: Service and Repair Front Floor Console Rear Cup Holder Replacement
Front Floor Console Rear Cup Holder Replacement
Removal Procedure
1. Pull all the way out on the cup holder. 2. Remove the screws from the cup holder track.
3. Remove the cup holder and the track from the console.
Installation Procedure
Notice: Refer to Fastener Notice.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Front Floor Console Front Cup Holder Replacement > Page 15265
1. Install the console track screws.
Tighten the screw to 2.5 N.m (22 lb in).
2. Verify the rear cup holder for correct operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Release Handle Replacement
Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Release
Handle Replacement
Instrument Panel Compartment Door Latch Release Handle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Release Handle Replacement > Page 15270
Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Replacement
Instrument Panel Compartment Door Latch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Release Handle Replacement > Page 15271
Glove Compartment: Service and Repair Instrument Panel Compartment Door Replacement
Instrument Panel Compartment Door Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information
> Service and Repair > Instrument Panel Compartment Door Latch Release Handle Replacement > Page 15272
Glove Compartment: Service and Repair Instrument Panel Compartment Replacement
Instrument Panel Compartment Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-67-007 > Apr > 08 > Interior - Rear of Headliner Appears Too
Short
Headliner: Customer Interest Interior - Rear of Headliner Appears Too Short
TECHNICAL
Bulletin No.: 08-08-67-007
Date: April 29, 2008
Subject: Headlining Trim Panel Appears Cut Too Short (Relocate OnStar(R)/Radio Wire Harness
and Antenna Connector)
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent 2008 Suzuki XL-7
Built Prior to April 21, 2008 with OnStar(R) (RPO UE1)
Condition
Some customers may comment on the headliner substrate appearing to be cut too short at the
headliner edge towards the rear of the vehicle.
Cause
The picture above shows the current location of the two connectors that is interfering with the
energy absorbing foam.
This may be caused by interference of the OnStar(R)/Radio wire harness and antenna connector
being routed where the energy absorbing foam is located at the rear header.
Correction
Technicians are to relocate the OnStar(R)/Radio wire harness and antenna connector away from
the energy absorbing foam using the procedure below.
Important:
DO NOT replace the headlining trim panel.
Important:
You do not have to drop the whole headliner to do this procedure.
1. Lower the rear of the headliner as needed-enough to access the OnStar(R)/Radio wire harness
and antenna connector. Refer to published procedures in SI and use appropriate steps to lower the
headliner.
2. Remove the Radio antenna connector retaining clip from the body (white connector) and the wire
harness retaining clip-cut off the retaining clip end.
3. Trace the wire harness down along the rear corner pillar.
4. Disconnect the two wire harness retaining clips (see figure above).
5. Slide the harness up about 101 to 127 mm (4 to 5 in). Clip the harness retaining clips back to the
body in the rear corner pillar.
6. Wrap some foam tape around the radio antenna connector (1) as shown in the picture above.
7. Using a tie strap secure one part of the harness to the body (2) as shown in the picture above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Customer Interest: > 08-08-67-007 > Apr > 08 > Interior - Rear of Headliner Appears Too
Short > Page 15281
8. Secure the other part of the harness to the existing harness that runs along the roof line with a
tie strap (3).
9. Reinstall the headliner.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-007 > Apr > 08 > Interior - Rear of Headliner
Appears Too Short
Headliner: All Technical Service Bulletins Interior - Rear of Headliner Appears Too Short
TECHNICAL
Bulletin No.: 08-08-67-007
Date: April 29, 2008
Subject: Headlining Trim Panel Appears Cut Too Short (Relocate OnStar(R)/Radio Wire Harness
and Antenna Connector)
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent 2008 Suzuki XL-7
Built Prior to April 21, 2008 with OnStar(R) (RPO UE1)
Condition
Some customers may comment on the headliner substrate appearing to be cut too short at the
headliner edge towards the rear of the vehicle.
Cause
The picture above shows the current location of the two connectors that is interfering with the
energy absorbing foam.
This may be caused by interference of the OnStar(R)/Radio wire harness and antenna connector
being routed where the energy absorbing foam is located at the rear header.
Correction
Technicians are to relocate the OnStar(R)/Radio wire harness and antenna connector away from
the energy absorbing foam using the procedure below.
Important:
DO NOT replace the headlining trim panel.
Important:
You do not have to drop the whole headliner to do this procedure.
1. Lower the rear of the headliner as needed-enough to access the OnStar(R)/Radio wire harness
and antenna connector. Refer to published procedures in SI and use appropriate steps to lower the
headliner.
2. Remove the Radio antenna connector retaining clip from the body (white connector) and the wire
harness retaining clip-cut off the retaining clip end.
3. Trace the wire harness down along the rear corner pillar.
4. Disconnect the two wire harness retaining clips (see figure above).
5. Slide the harness up about 101 to 127 mm (4 to 5 in). Clip the harness retaining clips back to the
body in the rear corner pillar.
6. Wrap some foam tape around the radio antenna connector (1) as shown in the picture above.
7. Using a tie strap secure one part of the harness to the body (2) as shown in the picture above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-007 > Apr > 08 > Interior - Rear of Headliner
Appears Too Short > Page 15287
8. Secure the other part of the harness to the existing harness that runs along the roof line with a
tie strap (3).
9. Reinstall the headliner.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Headliner: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise
From The Sunroof Area
Sunroof / Moonroof Track: All Technical Service Bulletins Body - Rattling Noise From The Sunroof
Area
TECHNICAL
Bulletin No.: 09-08-67-001
Date: January 06, 2009
Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape)
Models: 2006-2009 Buick Lucerne 2003-2007 Cadillac CTS 2005-2009 Cadillac STS 2006-2009
Cadillac DTS 2005-2009 Chevrolet Cobalt, Equinox 2006-2009 Chevrolet HHR 2006-2009 Pontiac
Torrent 2007-2009 Pontiac G5 2004-2007 Saturn VUE
Condition
Some customers may comment of a rattling noise coming from the sunroof or roof area.
Cause
This condition may be caused by the inboard tox rivets, which retain the sunroof center support
beam to the side rails, pulling through the side rail track on one or both sides. This may cause the
support beam to rattle against the side rail track.
Correction
Important:
Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the
center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition
is noted.
Install flocking tape between the sunroof center support beam and the side rail track.
1. Following SI, lower the front portion of the headliner enough to gain access to the sunroof
module center support beam through the opening in the headliner.
2. Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1)
between the center support and the side rail track.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Headliner: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise
From The Sunroof Area > Page 15293
3. Look for separation of the center support beam and the side rail track.
4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent,
approximately 152 mm (6 in) in length.
5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to
separate the center support beam and the side rail track.
6. Ensure that the flocking tape is positioned underneath the complete width of the center support
beam.
7. Reinstall the headliner.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Headliner: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise
From The Sunroof Area > Page 15299
3. Look for separation of the center support beam and the side rail track.
4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent,
approximately 152 mm (6 in) in length.
5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to
separate the center support beam and the side rail track.
6. Ensure that the flocking tape is positioned underneath the complete width of the center support
beam.
7. Reinstall the headliner.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15300
Headliner: Service and Repair
Headlining Trim Panel Replacement
Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the
headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the
garnish trim. Failure to do so could result in personal injury.
Notice: Use care when working around the head curtain inflator module. Sharp tools may puncture
the curtain airbag. If the head curtain inflator module is damaged in any way, it must be replaced.
Notice: If a vehicle is equipped with a head curtain inflator module ensure that the inflator module
and tether are undamaged. If tether or curtain airbag are damaged in any way, they must be
replaced.
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the sunshade. 3.
Remove the optional reading lamp cover.
4. Disconnect the optional OnStar(R) microphone harness.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15301
5. Disconnect the optional sunroof switch. 6. Remove the windshield upper garnish molding. 7.
Remove the upper center pillar molding. 8. Remove the dome lamp. 9. Remove the lock pillar
garnish molding.
10. Remove the rear corner garnish molding. 11. Remove the coat hooks.
12. Remove the rear pushpin. 13. Pull back the quarter trim panel. Refer to Rear Quarter Lower
Trim Panel Replacement. 14. Remove the door seal from the headliner edge.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15302
15. Disconnect the headliner electrical connector behind the trim panel. 16. Fold the passenger
seat flat and the driver seat forward.
17. Carefully disengage the hook and loop and the magnet attachments from the headliner and
remove the headliner out from the liftgate opening.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15303
1. Position the headliner into the vehicle through the liftgate opening. 2. Push on the hook and loop
and the magnet attachments to partially secure the liner.
3. Install the pushpin fastener at the rear of the headliner. 4. Secure the weatherstrip over the edge
of the headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15304
5. Connect the sunroof switch electrical connectors.
6. Connect the OnStar(R) microphone electrical connector. 7. Install the reading lamp cover. 8.
Connect the OnStar(R) electrical connector. 9. Install the sunshades.
10. Install the windshield upper garnish molding. 11. Install the center pillar molding. 12. Install the
dome lamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information >
Technical Service Bulletins > Page 15305
13. Connect the headliner electrical connectors behind the cargo area trim panel. Connect the clips
holding the wire to the metal. 14. Install the driver side quarter trim panel. 15. Install the lock pillar
garnish moldings. 16. Install the rear garnish molding. 17. Install the coat hooks. 18. Enable the
SIR system. Refer to SIR Disabling and Enabling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information >
Service and Repair
Scuff Plate: Service and Repair
Liftgate Door Sill Plate Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service
and Repair > Sunshade Anchor Replacement
Sun Visor: Service and Repair Sunshade Anchor Replacement
Sunshade Anchor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service
and Repair > Sunshade Anchor Replacement > Page 15313
Sun Visor: Service and Repair Sunshade Replacement
Sunshade Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement
Trim Panel: Service and Repair Body Rear Corner Garnish Molding Replacement
Body Rear Corner Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15318
Trim Panel: Service and Repair Center Pillar Lower Garnish Molding Replacement
Center Pillar Lower Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15319
Trim Panel: Service and Repair Center Pillar Upper Garnish Molding Replacement
Center Pillar Upper Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15320
Trim Panel: Service and Repair Liftgate Trim Panel Replacement
Liftgate Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15321
Trim Panel: Service and Repair
Body Rear Corner Garnish Molding Replacement
Body Rear Corner Garnish Molding Replacement
Center Pillar Lower Garnish Molding Replacement
Center Pillar Lower Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15322
Center Pillar Upper Garnish Molding Replacement
Center Pillar Upper Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15323
Liftgate Trim Panel Replacement
Liftgate Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15324
Lock Pillar Upper Garnish Molding Replacement
Lock Pillar Upper Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15325
Rear Quarter Lower Trim Panel Replacement
Rear Quarter Lower Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15326
Windshield Upper Garnish Molding Replacement
Windshield Upper Garnish Molding Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information >
Service and Repair > Body Rear Corner Garnish Molding Replacement > Page 15327
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
Door Lock Cylinder Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information
Key: Technical Service Bulletins Locks - Key Code Security Rules and Information
INFORMATION
Bulletin No.: 10-00-89-010
Date: May 27, 2010
Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada
Only)
Models:
2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior
Saturn and Saab 2002 and Prior Isuzu
Attention:
This bulletin has been created to address potential issues and questions regarding KeyCode
security. This bulletin should be read by all parties involved in KeyCode activity, including dealer
operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin
should be printed and maintained in the parts department for use as a reference.
Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009.
Where Are Key Codes Located?
General Motors provides access to KeyCodes through three sources when a vehicle is delivered to
a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a
small white bar coded tag sent with most new vehicles that also has the key code printed on it.
Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed
on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code
Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers.
The third source for Key codes is through the GM KeyCode Look-Up feature within the
OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model
years from the current model year.
When a vehicle is received by the dealership, care should be taken to safeguard the original
vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have
access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been
completed, the KeyCode information belongs to the customer and General Motors.
Tip
Only the original invoice contains key code information, a re-printed invoice does not.
GM KeyCode Look-Up Application for GM of Canada Dealers
All dealers should review the General Motors of Canada KeyCode Look-Up Policies and
Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates &
keys").
Please note that the KeyCode Access site is restricted. Only authorized users should be using this
application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently
goes back 17 years from current model year.
Important notes about security:
- Users may not access the system from multiple computers simultaneously.
- Users may only request one KeyCode at a time.
- KeyCode information will only be available on the screen for 2 minutes.
- Each user is personally responsible for maintaining and protecting their password.
- Never share your password with others.
- User Id's are suspended after 6 consecutive failed attempts.
- User Id's are disabled if not used for 90 days.
- Processes must be in place for regular dealership reviews.
- The Parts Manager (or assigned management) must have processes in place for employee
termination or life change events. Upon termination individuals access must be turned off
immediately and access should be re-evaluated upon any position changes within the dealership.
- If you think your password or ID security has been breached, contact Dealer Systems Support at
1-800-265-0573.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 15337
Each user will be required to accept the following agreement each time the KeyCode application is
used.
Key Code User Agreement
- Key codes are proprietary information belonging to General Motors Corporation and to the vehicle
owner.
- Unauthorized access to, or use of, key code information is unlawful and may subject the user to
criminal and civil penalties.
- This information should be treated as strictly confidential and should not be disclosed to anyone
unless authorized.
I will ensure that the following information is obtained prior to releasing any Key Code information:
1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership.
Registration should have normal markings from the Province that issued the registration and
possibly the
receipt for payment recorded as well.
Important
- GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving
out key codes.
- When the ownership of the vehicle is in doubt, dealership personnel should not provide the
information.
Key code requests should never be received via a fax or the internet and key codes should never
be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the
expected manner that dealers will use to release a key code or as otherwise stipulated in this
bulletin or other materials.
- Key codes should NEVER be sent via a fax or the internet.
- Each Dealership should create a permanent file to document all KeyCode Look Up transactions.
Requests should be filed by VIN and in each folder retain copies of the following:
- Government issued picture ID (Drivers License)
- Registration or other proof of ownership.
- Copy of the paid customer receipt which has the name of the employee who cut and sold the key
to the customer.
- Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up
to either GM or law enforcement officials.
- Dealership Management has the ability to review all KeyCode Look-Up transactions.
- Dealership KeyCode documentation must be retained for two years.
Frequently Asked Questions (FAQs) for GM of Canada Dealers
How do I request a KeyCode for customer owned vehicle that is not registered?
Scrapped, salvaged or stored vehicles that do not have a current registration should still have the
ownership verified by requesting the vehicle title, current insurance policy and / or current lien
holder information from the customers financing source. If you cannot determine if the customer is
the owner of the vehicle, do not provide the key code information. In these cases, a short
description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on
file. Any clarifying explanation should be entered into the comments field.
How do I document a KeyCode request for a vehicle that is being repossessed?
The repossessor must document ownership of the vehicle by providing a court ordered
repossession order and lien-holder documents prior to providing key code information. Copies of
the repossessors Drivers License and a business card should be retained by the dealership for
documentation.
What do I do if the registration information is locked in the vehicle?
Every effort should be made to obtain complete information for each request. Each Dealership will
have to decide on a case by case basis if enough information is available to verify the customer's
ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and
or current lien information from the customers financing source. Dealership Management must be
involved in any request without complete information. If you cannot determine if the customer is the
owner of the vehicle, do not provide the key code information.
Can I get a print out of the information on the screen?
It is important to note that the Key Code Look Up Search Results contain sensitive and/or
proprietary information. For this reason GM recommends against printing it. If the Search Results
must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper
or illegal use.
Who in the dealership has access to the KeyCode application?
Dealership Parts Manager (or assigned management) will determine, and control, who is
authorized to access the KeyCode Look Up application. However, we anticipate that dealership
parts and service management will be the primary users of the application. The KeyCode Look Up
application automatically tracks each user activity session. Information tracked by the system
includes: User name, User ID, all other entered data and the date/time of access.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 15338
What if I input the VIN incorrectly?
If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN
or that the VIN has been entered incorrectly) the system will return an error message.
If I am an authorized user for the KeyCode application, can I access the application from home?
Yes.
What if I suspect key code misuse?
Your dealership should communicate the proper procedures for requesting key codes. Any
suspicious activity either within the dealership or externally should be reported to Dealer Systems
Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
Whose key codes can I access through the system?
At this time the following Canadian vehicle codes are available through the system: Chevrolet,
Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu
(up to 2002 model year) for a maximum of 17 model years.
What should I do if I enter a valid VIN and the system does not produce any key code information?
Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This
may be the result of new vehicle information not yet available. In addition, older vehicle information
may have been sent to an archive status. If you do not receive a key code returned for valid VIN,
you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
How do I access KeyCodes if the KeyCode Look-up system is down?
If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling
dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have
the customer contact Roadside assistance, OnStar if subscribed, or 911.
What should I do if the KeyCode from the look-up system does not work on the vehicle?
On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In
cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting
equipment that the key has been cut correctly. If the key has been cut correctly you may be able to
verify the proper KeyCode was given through the original selling dealer. When unable to verify the
KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at
1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock
cylinder may have been changed. In these situations following the proper SI document for recoding
a key or replacing the lock cylinder may be necessary.
How long do I have to keep KeyCode Records?
Dealership KeyCode documentation must be retained for two years.
Can I get a KeyCode changed in the Look-Up system?
Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed.
Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892.
What information do I need before I can provide a driver of a company fleet vehicle Keys or
KeyCode information?
The dealership should have a copy of the individual's driver's license, proof of employment and
registration. If there is any question as to the customer's employment by the fleet company, the
dealer should attempt to contact the fleet company for verification. If there is not enough
information to determine ownership and employment, this information should not be provided.
How do I document a request from an Independent Repair facility for a KeyCode or Key?
The independent must provide a copy of their driver's license, proof of employment and signed
copy of the repair order for that repair facility. The repair order must include customer's name,
address, VIN, city, province and license plate number. Copies of this information must be included
in your dealer KeyCode file.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins >
Locks - Key Code Security Rules and Information > Page 15339
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component
Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component
Information > Diagrams
Keyless Entry Receiver: Diagrams
Component Connector End Views - Continued
Remote Control Door Lock Receiver (RCDLR)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip
Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter
Diagnostic Tip
INFORMATION
Bulletin No.: 09-08-52-004A
Date: January 08, 2010
Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter
When Transmitter Battery is Weak or Dead
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade
ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR,
Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra,
Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn
AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2
Supercede: This bulletin is being revised to update the models and model years. Please discard
Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories).
Follow these procedures if a customer comments that their GM Accessory 2-way transmitter
stopped communicating with the vehicle.
About GM Accessory 2-Way Remote Start
The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a
2-way advanced remote start system, but often the 2-way transmitter may only be coded to one
vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter
will enter second vehicle mode and will not control the original vehicle until a subsequent double
press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of
the 2-way transmitter should be thought of as an individual transmitter with its own unique code.
Test the Transmitter Battery
Note
This test should be performed prior to releasing the vehicle or transmitter to the customer.
All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or
replacement of a transmitter battery using the following procedure.
1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of
the unlock button, observe the battery gauge located in the upper right corner of the LCD display.
The gauge should read
full (three bars inside the battery icon).
If after having a new battery installed, the battery goes dead within five months, the transmitter
could have high sleep current, causing the battery to go dead. Replace the transmitter.
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition
exhibited is resolved without completing every step, the remaining steps do not need to be
performed.
Determine if Transmitter is in Second Vehicle Mode
1. Press and release any of the face buttons on the 2-way transmitter and observe the display on
power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be
displayed on the left side of the transmitter display. Is the 2-way
transmitter in second vehicle mode?
If Yes, the 2-way transmitter is working properly.
- Press and release the left side button twice within one second. The 2-way transmitter should exit
second vehicle mode.
- Press and release the lock button. Press and release the unlock button.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 15352
- Confirm that the vehicle responds with the appropriate lock and unlock function.
- If Yes , the 2-way transmitter was in mode B.
- Press and release the left side button twice within one second. The 2-way transmitter should
enter second vehicle mode.
- Use the "next available slot" method in the scan tool to program the 2-way transmitter to the
2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI.
- Both vehicle modes of the 2-way transmitter should now be coded to the vehicle.
If No:
The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal
diagnostic procedures.
Parts Information
For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts
Catalog or Corporate Bulletin Number 09-00-89-025A.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 15353
Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote
Start
INFORMATION
Bulletin No.: 09-00-89-025A
Date: October 26, 2009
Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information
Models:
2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT
2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche,
Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse
2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent
2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA,
OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY
Attention:
This bulletin does not apply to GMODC dealers.
Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin
Number 09-00-89-025 (Section 00 - General Information).
This bulletin is being published to provide information on locating service part numbers for GM
Accessory, 2-Way Advanced Remote Start Systems.
Dealers should consult the chart below and use the correct service part. Dealers should not use
entire kit for warranty or repair work.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 15354
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 15355
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start
Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter
Diagnostic Tip > Page 15356
Parts Information
Service parts common to all 2-Way Advanced Remote Start Systems
Transmitter Battery 12493150
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Technical Service Bulletins > Keyless Entry - Transmitter Button Inop/Won't Program
Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Transmitter Button
Inop/Won't Program
INFORMATION
Bulletin No.: 10-08-52-003
Date: July 21, 2010
Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to
Vehicle
Models:
2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007
Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade,
Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox
2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express
2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali
Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK
2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry
Attention:
This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A
copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry
(RKE) transmitter operation.
This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may
be inoperative intermittently or in which a particular button(s) does not work.
To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are
depressed longer than 30 seconds. The disabled button or buttons will remain disabled until
another button that has not been disabled is pressed.
If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed
to a vehicle, press and release each and every button on the fob one at a time until you find one
that works then retest the other buttons. If all buttons are now working, the button(s) were disabled
and the transmitter is working as designed.
If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics
as shown in SI.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component
Information > Technical Service Bulletins > Page 15361
Keyless Entry Transmitter: Service and Repair
Transmitter Programming
Next Available Slot
Important:
* On some vehicles, keyless entry transmitters may also be programmed using the driver
information center (DIC). Refer to the vehicle owners manual for information.
* Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless
entry program mode. This prevents the programming of the transmitters to the incorrect vehicle.
This procedure will program keyless entry transmitters in sequential order. If two transmitters are
currently learned to the vehicle as transmitters 1 and 2, using this procedure will learn the next
transmitter are transmitter 3, and so on.
1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select
Program Key Fobs. 2. Select Next Available Slot. The vehicle chime will sound two times to
indicate programming mode has been entered. Follow the on-screen
instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm
the programming.
3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF,
exit the vehicle, and operate the transmitter
functions in order to verify correct system operation.
Invalidate All Fobs
Important:
* On some vehicles, keyless entry transmitters may also be programmed using the driver
information center (DIC). Refer to the vehicle owners manual for information.
* All transmitters which are to be recognized by the remote control door lock receiver (RCDLR)
must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is
made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle
are not learned at this time, they will become inoperative and require additional programming.
* Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless
entry program mode. This prevents the programming of the transmitters to the incorrect vehicle.
This procedure will first erase all known keyless entry transmitters. After all transmitters are erased,
the procedure will being to program keyless entry transmitters in sequential order, beginning with
transmitter 1.
1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select
Program Key Fobs. 2. Select Invalidate All Fobs. This will erase all learned transmitters and
prepare the RCDLR to learn new transmitters. Follow the on-screen
instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm
the programming.
3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF,
exit the vehicle, and operate the transmitter
functions in order to verify correct system operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component
Information > Locations
Power Door Lock Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations
Power Door Lock Switch: Locations
Door Component Views
Driver Door Components
1 - Outside Rearview Mirror - Driver 2 - Window Motor - Driver 3 - Door Lock Switch - Driver 4 Door Latch - Driver
Passenger Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 15369
1 - Door Latch - Front Passenger 2 - Door Lock Switch - Front Passenger 3 - Window Motor - Front
Passenger 4 - Outside Rearview Mirror - Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 15370
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock Switch - Driver
Door Lock Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 15371
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component
Information > Locations > Page 15372
Power Door Lock Switch: Service and Repair
Door Lock Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical
Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time
Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time
INFORMATION
Bulletin No.: 08-08-64-011A
Date: February 25, 2010
Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance
Models:
2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories).
Defrosting Time/Performance Concern
The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM
vehicles is slower to defrost than the passenger side outside rearview mirror.
This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as
the traditional glass on the passenger side mirror. The heating elements for the mirrors on both
sides draw the same wattage, therefore the driver's side mirror will take approximately twice as
long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a
customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function
based upon this information prior to replacing the mirror.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
Power Mirror Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Page 15381
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Page 15382
Power Mirror Switch: Diagrams
Component Connector End Views - Continued
Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations >
Page 15383
Power Mirror Switch: Service and Repair
Power Mirror Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint
Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page
15393
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored
Spots in Paint
Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored
Spots in Paint > Page 15399
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior
to Painting
Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting
INFORMATION
Bulletin No.: 08-08-51-002
Date: March 12, 2008
Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation
Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3
The purpose of this bulletin is to inform the technician that General Motors has made a change in
the primer it uses for TPO plastic for service parts. This new primer comes in several different
colors from five different suppliers. This change affects the cleaning process of the painting
operation. The new process is as follows.
1. Wash with soap and water.
2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your
paint supplier for product recommendations.
3. Scuff sand per your paint suppliers recommendations.
Note:
The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not
have any affect on this primer.
4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner).
All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You
may find other TPO parts with this primer. If the technician has a question as to the type of plastic
they are painting, inspect the back of the part for the plastic symbol (TPO).
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide
Trunk / Liftgate Weatherstrip: All Technical Service Bulletins Body - General Water Leak Diagnostic
Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide > Page 15409
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide > Page 15410
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide > Page 15411
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide > Page 15412
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > 08-08-57-001A > Oct > 08 > Body - General Water Leak
Diagnostic Guide > Page 15413
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 15414
Paint: By Symptom
Technical Service Bulletin # 05-08-51-008C Date: 090622
Body - Bumps or Rust Colored Spots in Paint
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 15415
Use the chemical manufacturers listed below, or equivalent:
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or
(214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com
[email protected]
E038 Fallout Gel or E038E Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Technical Service Bulletin # 05-08-51-008C Date: 090622
Body - Bumps or Rust Colored Spots in Paint
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 15416
TECHNICAL
Bulletin No.: 05-08-51-008C
Date: June 22, 2009
Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust)
Models:
1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2
2006-2010 HUMMER H3 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 05-08-51-008B (Section 08 - Body and Accessories).
Condition
Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust.
Cause
Rail dust comes from tiny iron particles produced from the friction between train wheels and the
tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the
vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material
can lay on top of, or become embedded in, the paint surface.
Correction
Because the severity of the condition varies, proper diagnosis of the damage is critical to the
success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick
up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials
recommended to repair rail dust or iron dust:
1. GEL TYPE OXALIC ACID:
- Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel
consistency.
2. CLAY TYPE NON-ACID BASED:
- Requires surface lubricant during use. - Has different grades available.
Caution
Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down
the iron particles embedded in the finish. When working with rail dust remover, use the necessary
safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions
closely because it may require special handling and disposal.
If, upon inspection, some particles are still present, the various chemical manufacturer's processes
can be repeated.
After the removal process, small pits may remain in the clearcoat and can be corrected, in most
cases, with a finesse/polish operation.
Procedure
1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during
the removal process. DO NOT PERFORM THE
REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY
PANELS.
2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a
wax and grease remover. 3. Perform the removal process according to the chemical
manufacturer's directions.
Once the damage has been repaired, the final step involves a polishing process.
Rail Dust Remover Manufacturers
Use the chemical manufacturers listed below, or equivalent:
Auto Magic(R) or Clay Magic(R) products available from:
Auto Wax Company, Inc.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical
Service Bulletins > All Other Service Bulletins for Paint: > Page 15417
1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax
(214) 634-1342 www.automagic.com
[email protected] E038 Fallout Gel or E038E
Liquid Fallout Remover II available from:
Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll
Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com
[email protected] *We
believe these sources and their products to be reliable. There may be additional manufacturers of
such products. General Motors does not endorse, indicate any preference for or assume any
responsibility for the products from these firms or for any such items which may be available from
other sources.
If rail dust remover is not available in your area, call one of the numbers listed above for a
distributor near your location.
Warranty Information (excluding Saab U.S. Models)
Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information
regarding warranty coverage for this condition.
Important In certain cases where the vehicle finish is severely damaged and the actual repair time
exceeds the published time, the additional time should be submitted in the "Other Labor Hours"
field.
Warranty Information (Saab U.S. Models)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service
Precautions > Technician Safety Information
Paint: Technician Safety Information
Antenna Mast Paint Notice
Notice: Use tape on the tool surface so that you do not damage the paint on the antenna mast.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service
Precautions > Technician Safety Information > Page 15420
Paint: Vehicle Damage Warnings
Brake Fluid Effects on Paint and Electrical Components Notice
Brake Fluid Effects on Paint and Electrical Components Notice
Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables.
Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any
brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any
brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to
wipe away the fluid.
Clearcoat/Ultraviolet Screeners Notice
Clearcoat/Ultraviolet Screeners Notice
Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat
contains ultraviolet screeners. Do not finesse sand more than what is required to remove the
defect.
Paint Damage Notice
Paint Damage Notice
Notice: To avoid paint damage, protect the area surrounding the part which you are removing or
installing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Paint Identification
Paint: Application and ID Paint Identification
Paint Identification
Caution: Exposure to isocyanates during paint preparation and application processes can cause
severe breathing problems. Read and follow all of the instructions from the manufacturers of
painting materials, equipment, and protective gear.
Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book
identifies the paint systems you may use.
Use the service parts identification label to identify the type of paint technology, paint codes, trim
level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard,
Anti-Theft, and Service Parts ID Label.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Paint Identification > Page 15423
Paint: Application and ID Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label
Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Paint Identification > Page 15424
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application
and ID > Page 15425
Paint: Service and Repair
Basecoat/Clearcoat Paint Systems
Caution: Exposure to isocyanates during paint preparation and application processes can cause
severe breathing problems. Read and follow all of the instructions from the manufacturers of
painting materials, equipment, and protective gear.
All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest
revision of the GM Approved Refinish Materials book GM P/N GM4901M-D to identify the paint
systems you may use that have been engineered to meet GM standards. The GM Approved
Refinish Materials book supplies all approved products, including volatile organic compound (VOC)
compliant regulations recommended by the individual manufacturer, and detailed procedures for
materials used in their paint system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Service and Repair
Keyless Entry Module: Service and Repair
Remote Control Door Lock Receiver Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-001
> Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: Customer Interest Electrical - No Crank/Start Discharged or Low
Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-001
> Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 15441
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/Start Discharged
or Low Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: >
10-08-50-001 > Feb > 10 > Electrical - No Crank/Start Discharged or Low Battery > Page 15447
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15448
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15449
Seat Heater Control Module: Diagrams
Component Connector End Views
Heated Seat Control Module X1 (KA1)
Heated Seat Control Module X2 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15450
Heated Seat Control Module X3 (KA1)
Heated Seat Control Module X4 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15451
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15452
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Technical Service Bulletins > Page 15453
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Diagrams
Sunroof / Moonroof Module: Diagrams
Component Connector End Views - Continued
Sunroof Control Module X1
Sunroof Control Module X2
Transfer Case Shift Control Module - C3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Diagrams > Page 15457
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Diagrams > Page 15458
Sunroof / Moonroof Module: Service and Repair
Sunroof Control Module Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
2. Depress the tab on the side of the control module. 3. With the tab depressed, slide the sunroof
control module toward the sunroof motor. This will release the control module from the sunroof
module.
4. Remove the control module from the sunroof module and disconnect the electrical connector.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Diagrams > Page 15459
1. Connect the electrical connector to the sunroof control module.
2. Insert the control module tabs into the sunroof module slots. 3. Slide the sunroof express module
away from the sunroof motor until it is fully engaged. 4. Verify the proper operation of the sunroof
before securing the headliner. 5. Install the headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay >
Component Information > Locations
Trunk / Liftgate Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component
Information > Specifications
Luggage Rack: Specifications
Fastener Tightening Specifications
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component
Information > Specifications > Page 15467
Luggage Rack: Service and Repair
Luggage Carrier Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade >
Component Information > Service and Repair
Sun Shade: Service and Repair
Sunroof Sunshade Replacement
Removal Procedure
1. Remove the sunroof window.
2. Remove the screws from the sunroof drip channel. 3. Remove the sunroof drip channel. 4. Slide
the sunshade forward to the closed position. 5. Push the spring retainer clips on the right side of
the sunshade inward to disengage them from the track using an upward lifting motion. 6. Remove
the sunshade from the sunroof module.
Installation Procedure
1. Engage one side of the sunshade by positioning the spring clips into the track. 2. Push the
spring retainer clips inward on the opposite side of the sunshade to engage them into the track.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade >
Component Information > Service and Repair > Page 15472
3. Slide the sunshade back and forth to ensure proper operation. 4. Slide the sunshade to the half
closed position. 5. Install the rear drain drip channel. 6. Install the sunroof window.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Diagrams
Sunroof / Moonroof Motor: Diagrams
Component Connector End Views - Continued
Sunroof Motor X1
Sunroof Motor X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Diagrams > Page 15476
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Diagrams > Page 15477
Sunroof / Moonroof Motor: Service and Repair
Sunroof Motor/Actuator Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
2. Remove the sunroof window.
3. Disconnect the sunroof motor harness. 4. Remove the screws securing the sunroof actuator to
the sunroof module. 5. Remove the sunroof motor.
Installation Procedure
1. Manually adjust the track to achieve a distance of (a) 44.5 mm (1.75 in) between the left slide
and track bracket. 2. Manually adjust the track to achieve a distance of (a) 44.5 mm (1.75 in)
between the right slide and track bracket.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Diagrams > Page 15478
3. Install the sunroof motor to the sunroof module.
Notice: Refer to Fastener Notice.
4. Install the sunroof motor screws.
Tighten the screws to 5 N.m (44 lb in).
5. Connect the electrical connectors to the sunroof motor. 6. Secure the electrical harness to the
sunroof module. 7. Verify the sunroof operation. 8. Install the sunroof window. 9. Install the
headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front Headliner Components
1 - Dome Lamp - Center (-UUC) 2 - Cellular Telephone Microphone (UE1) 3 - Sunroof Switch
(CF5) 4 - Courtesy / Map Lamp
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 15482
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views - Continued
Sunroof Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 15483
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Removal Procedure
1. Pull gently at front of reading lamp cover to disengage retaining clips. 2. Rotate cover rearward
until rear attaching hooks are released. 3. Disconnect sunroof switch harness from sunroof switch.
4. Remove sunroof switch fasteners and remove sunroof switch.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 15484
1. Install sunroof switch with fasteners.
Tighten sunroof switch to 2.5 N.m (22 lb in)
2. Connect sunroof switch harness to sunroof switch. 3. Position front reading lamp cover into rear
attaching hooks. 4. Rotate front reading lamp cover into lamp assembly forward, then snap cover
into place. 5. Function sunroof switch to ensure proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track:
> 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area
Sunroof / Moonroof Track: Customer Interest Body - Rattling Noise From The Sunroof Area
TECHNICAL
Bulletin No.: 09-08-67-001
Date: January 06, 2009
Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape)
Models: 2006-2009 Buick Lucerne 2003-2007 Cadillac CTS 2005-2009 Cadillac STS 2006-2009
Cadillac DTS 2005-2009 Chevrolet Cobalt, Equinox 2006-2009 Chevrolet HHR 2006-2009 Pontiac
Torrent 2007-2009 Pontiac G5 2004-2007 Saturn VUE
Condition
Some customers may comment of a rattling noise coming from the sunroof or roof area.
Cause
This condition may be caused by the inboard tox rivets, which retain the sunroof center support
beam to the side rails, pulling through the side rail track on one or both sides. This may cause the
support beam to rattle against the side rail track.
Correction
Important:
Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the
center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition
is noted.
Install flocking tape between the sunroof center support beam and the side rail track.
1. Following SI, lower the front portion of the headliner enough to gain access to the sunroof
module center support beam through the opening in the headliner.
2. Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1)
between the center support and the side rail track.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Track:
> 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area > Page 15493
3. Look for separation of the center support beam and the side rail track.
4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent,
approximately 152 mm (6 in) in length.
5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to
separate the center support beam and the side rail track.
6. Ensure that the flocking tape is positioned underneath the complete width of the center support
beam.
7. Reinstall the headliner.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Track: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area
Sunroof / Moonroof Track: All Technical Service Bulletins Body - Rattling Noise From The Sunroof
Area
TECHNICAL
Bulletin No.: 09-08-67-001
Date: January 06, 2009
Subject: Sunroof Frame Tox Rivet Rattle (Install Flocking Tape)
Models: 2006-2009 Buick Lucerne 2003-2007 Cadillac CTS 2005-2009 Cadillac STS 2006-2009
Cadillac DTS 2005-2009 Chevrolet Cobalt, Equinox 2006-2009 Chevrolet HHR 2006-2009 Pontiac
Torrent 2007-2009 Pontiac G5 2004-2007 Saturn VUE
Condition
Some customers may comment of a rattling noise coming from the sunroof or roof area.
Cause
This condition may be caused by the inboard tox rivets, which retain the sunroof center support
beam to the side rails, pulling through the side rail track on one or both sides. This may cause the
support beam to rattle against the side rail track.
Correction
Important:
Once the sunroof module is bolted into the roof ring of the vehicle, the support provided by the
center beam is no longer necessary. DO NOT replace the sunroof frame when the above condition
is noted.
Install flocking tape between the sunroof center support beam and the side rail track.
1. Following SI, lower the front portion of the headliner enough to gain access to the sunroof
module center support beam through the opening in the headliner.
2. Check both sides of the center support beam for loose rivets (2) by inserting a trim stick (1)
between the center support and the side rail track.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Track: > 09-08-67-001 > Jan > 09 > Body - Rattling Noise From The Sunroof Area > Page 15499
3. Look for separation of the center support beam and the side rail track.
4. Cut a piece of Kent-Automotive(TM) 30 mm wide BRS Flocking tape, or equivalent,
approximately 152 mm (6 in) in length.
5. Install the flocking tape (1) underneath the center support beam using the trim stick (2) to
separate the center support beam and the side rail track.
6. Ensure that the flocking tape is positioned underneath the complete width of the center support
beam.
7. Reinstall the headliner.
Parts Information
Warranty Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Technical Service Bulletins > Page 15500
Sunroof / Moonroof Track: Service and Repair
Sunroof Track Timing/Synchronization
1. Before retiming the module, the actuator /motor must be removed. Refer to Sunroof
Motor/Actuator Replacement.
Important: If the sunroof actuator is the only part being serviced, follow the power sunroof actuator
replacement procedure for the sunroof actuator to sunroof window timing. Refer to Sunroof
Motor/Actuator Replacement.
A new replacement power sunroof actuator is set to the fully closed and flush position at the
factory.
2. Remove the sunroof window. 3. Fabricate a gage (2) 46.8 +/- 0.5 mm (1.84 in) wide (A).
A piece of thick paper will work.
4. Set the gage into the track near the rear of the opening between the move drive slide (1) and the
bracket. 5. Move the drive slide fore or aft in order to get the proper setting. 6. Repeat steps 3 and
4 for the other side. 7. Install the sunroof window. 8. Install the sunroof actuator. 9. Operate the
sunroof through all functions to ensure proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair
Sunroof / Moonroof Windguard: Service and Repair
Sunroof Air Deflector Replacement
Removal Procedure
1. Cycle the sunroof window to the rear.
2. Push down on the right front side of the air deflector.
3. Do the following while holding the right side down:
* Push the left front side of the air deflector towards the right side.
* Pull up on the left side until the lower tab clears the roof opening.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Page 15504
4. Swing the air deflector in an upward arc, rearward, to disengage air deflector from the hooks on
both sides of the sunroof module. 5. Remove the air deflector from the vehicle.
Installation Procedure
1. Engage the rear of the air deflector into the side hooks on the sunroof module. 2. Arc the air
deflector in a forward motion.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Page 15505
3. Push the right side of the air deflector down into the roof opening.
4. Push the left front side of the air deflector inward and down so the tab clears the roof opening. 5.
Close the sunroof window.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair > Procedures
Sunroof / Moonroof Drain: Procedures
Sunroof Drain Inspection and Cleaning
Drain Hose Routing
A drain trough encircles the sunroof window panel and water is drained off by the drain hoses
located at each corner of the housing. A drain channel spans across the sunroof module at the rear
of the window panel and directs water into the trough.
1. Ensure the front drain hoses are routed down the windshield pillars and out the center of the
pillar between the door hinges. Ensure the hoses are
not kinked. Replace any torn or cracked hose.
2. Ensure the rear drain hoses are routed through the rear pillars and out of the rocker panel.
Ensure the rear hoses are properly routed in the metal
roof slot and taped in place. Replace any torn or cracked hoses.
Plugged Drain Hose
If a waterleak has occurred inspect for a plugged drain hose at each corner of trough.
1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the
module housing trough. Inspect each corner to confirm the drain hose is draining
water.
Caution: Wear safety glasses in order to avoid eye damage.
3. Use compressed air, 35 psi or less to blow out any drain hose that is plugged. 4. Test the system
again. 5. If the hose remains plugged, inspect to see it is properly routed and does not have a kink.
6. Remove any hoses that remain plugged. 7. Remove the blockage.
1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in
order to blow out any remaining debris.
8. Install the hose.
Disconnected Drain Hose
Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to
obtain partial access to the drain hoses and to inspect for disconnected hoses.
1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headlining Trim
Panel Replacement. 3. Connect any disconnected hoses. 4. Ensure that the drain hoses are
properly routed in the metal roof slot and secured into place.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15510
Sunroof / Moonroof Drain: Removal and Replacement
Sunroof Housing Front Drain Hose Replacement
Sunroof Housing Front Drain Hose Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
2. Remove the front drain hose from the sunroof module. 3. Remove tape from the drain hose. 4.
Remove the front drain hose from the retaining clips.
5. Pull the front drain hose out of the front hinge pillar.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15511
Installation Procedure
1. Push the drain hose into the hole in the front hinge pillar. 2. Connect the front drain hose to the
retaining clips.
3. Connect the drain hose to the sunroof module. 4. Install the headliner.
Sunroof Housing Rear Drain Hose Replacement
Sunroof Housing Rear Drain Hose Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15512
2. Remove the rear drain hoses from the sunroof module. 3. Remove the tape from the drain hose.
4. Remove the upper portion of the rear drain hoses from the retaining clips. 5. Remove the rear
side trim panels. 6. Remove the lower portion of the rear drain hoses from the retaining clips. 7.
Pull the rear drain hoses up through the side rail.
Installation Procedure
1. Route the rear drain hose down through the access hole in the side rail.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair > Procedures > Page 15513
2. Push the end of the rear drain hoses down into the rear compartment opening. 3. Clip the lower
portion of the rear drain hoses into position. 4. Install the rear side trim panels. 5. Clip the upper
portion of the rear drain hoses into position.
6. Install the rear drain hoses to the sunroof module. 7. Install the headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Diagrams
Sunroof / Moonroof Module: Diagrams
Component Connector End Views - Continued
Sunroof Control Module X1
Sunroof Control Module X2
Transfer Case Shift Control Module - C3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Diagrams > Page 15517
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Diagrams > Page 15518
Sunroof / Moonroof Module: Service and Repair
Sunroof Control Module Replacement
Removal Procedure
1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will
lower the headliner enough to gain access to the
part. Refer to Headlining Trim Panel Replacement.
2. Depress the tab on the side of the control module. 3. With the tab depressed, slide the sunroof
control module toward the sunroof motor. This will release the control module from the sunroof
module.
4. Remove the control module from the sunroof module and disconnect the electrical connector.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Diagrams > Page 15519
1. Connect the electrical connector to the sunroof control module.
2. Insert the control module tabs into the sunroof module slots. 3. Slide the sunroof express module
away from the sunroof motor until it is fully engaged. 4. Verify the proper operation of the sunroof
before securing the headliner. 5. Install the headliner.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Adjustments
Sunroof / Moonroof Panel: Adjustments
Sunroof Window Height and Opening Fit Adjustment
Important: Correct adjustment cannot be achieved if the sunroof window is closed from vent
position.
1. Cycle the sunroof window from full open to closed position.
2. Loosen the adjusting screws. 3. Adjust the corners of the front window panel using the following
guidelines:
* Adjust the front of the sunroof window to -0.0 mm (-1.5- in) below the top surface of the roof
panel.
* Adjust the rear of the sunroof window to -1.5 mm (-0.0 in) above the top surface of the roof panel.
* Adjust the rear edge of the front sunroof window to leading edge of the rear window to +1.0 mm
(-0.05 in) to the panel shingling.
Notice: Refer to Fastener Notice.
4. Install the sunroof window adjustment screws.
Tighten the sunroof window adjusting screws to 6 N.m (53 lb in).
5. Cycle sunroof window through all positions. 6. Inspect the sunroof window adjustment. Adjust if
necessary.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Adjustments > Page 15523
Sunroof / Moonroof Panel: Service and Repair
Sunroof Window Replacement
Removal Procedure
Notice: In order to prevent damage to the paint, mask the roof panel in front of the sunroof opening
using masking tape and paper.
1. Cycle the sunroof window to the vent position. 2. Slide the sunshade rearward.
3. Remove the sunroof window screws on both sides.
Important: If operating the sunroof without the window, refer to Sunroof Air Deflector Replacement.
4. Lift the sunroof window from the sunroof opening.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Adjustments > Page 15524
1. Position the sunroof window into the opening. 2. Install the sunroof window screws. Do not
tighten the screws. 3. Carefully close the sunroof window from the vent position to the full closed
position. 4. Adjust the sunroof window. Refer to Sunroof Window Height and Opening Fit
Adjustment.
Notice: Refer to Fastener Notice.
5. Tighten the sunroof window screws.
Tighten the screws to 5 N.m (44 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Guide Replacement (Fold Flat)
Head Rest: Service and Repair Front Seat Head Restraint Guide Replacement (Fold Flat)
Front Seat Head Restraint Guide Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Guide Replacement (Fold Flat) > Page 15530
Head Rest: Service and Repair Front Seat Head Restraint Guide Replacement (Non-Fold Flat)
Front Seat Head Restraint Guide Replacement (Non-Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Guide Replacement (Fold Flat) > Page 15531
Head Rest: Service and Repair Front Seat Head Restraint Replacement
Front Seat Head Restraint Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Guide Replacement (Fold Flat) > Page 15532
Head Rest: Service and Repair Rear Seat Head Restraint Replacement
Rear Seat Head Restraint Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair >
Front Seat Head Restraint Guide Replacement (Fold Flat) > Page 15533
Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement
Rear Seat Head Restraint Guide Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical
Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information
Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest
Information
INFORMATION
Bulletin No.: 10-08-50-003A
Date: March 24, 2011
Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom
Upholstery or Other Comfort Enhancing Devices
Models:
2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 10-08-50-003 (Section 08 - Body and Accessories).
Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE
HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS
RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD
RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED
DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE
OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS
INCURRED.
You may have a customer with a concern that the head restraint is uncomfortable or sits too far
forward. The front driver and passenger seats are equipped with head restraints that have been
designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle
has its own specifically designed head restraint.
The head restraints should only be used in the vehicle for which they were designed. The head
restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or
head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or
head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket
comfort enhancing pad or device, is installed.
Never modify the design of the head restraint or remove the head restraint from the vehicle as this
may interfere with the operation of the seating and restraint systems and may prevent proper
positioning of the passenger within the vehicle.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations
Power Seat Motor: Locations
Passenger Compartment/Roof Component Views
Power Driver Seat Components
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 15541
Power Seat Motor: Diagrams
Component Connector End Views - Continued
Seat Front Vertical Motor - Driver
Telescoping Actuator C1
Seat Rear Vertical Motor - Driver
Telescoping Actuator C1
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 15542
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations >
Page 15543
Power Seat Motor: Service and Repair
Power Seat Adjuster Mechanism Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Passenger Compartment/Roof Component Views
Power Seat Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Power Driver Seat Components
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Passenger Compartment/Roof Component Views > Page 15548
Power Seat Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Passenger Compartment/Roof Component Views > Page 15549
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations >
Page 15550
Power Seat Switch: Diagrams
Component Connector End Views - Continued
Seat Adjuster Switch Driver
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Power Seat Switch: Service and Repair Driver Seat and Passenger Seat Adjuster Switch Knob
Replacement
Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement > Page 15553
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and
Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement > Page 15554
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat)
Seat Back: Service and Repair Driver Seat and Passenger Seat Back Cushion Finish Panel
Replacement (Fold Flat)
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15559
Seat Back: Service and Repair Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)
Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15560
Seat Back: Service and Repair Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)
Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15561
Seat Back: Service and Repair Front Seat Recliner Mechanism Replacement
Front Seat Recliner Mechanism Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15562
Seat Back: Service and Repair
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat)
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat)
Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)
Front Seat Back Recliner Inner Trim Panel Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15563
Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)
Front Seat Back Recliner Outer Trim Panel Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15564
Front Seat Recliner Mechanism Replacement
Front Seat Recliner Mechanism Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15565
Rear Seat Back Cushion Trim Panel Replacement
Rear Seat Back Cushion Trim Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15566
Front Seat Back Cushion Cover and Cushion Pad Replacement (Fold Flat)
Front Seat Back Cushion Cover and Cushion Pad Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15567
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15568
Front Seat Back Cushion Cover and Cushion Pad Replacement (Non-Fold Flat)
Front Seat Back Cushion Cover and Cushion Pad Replacement (Non-Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15569
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15570
Front Seat Back Frame Replacement (Fold Flat)
Front Seat Back Frame Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15571
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15572
Front Seat Back Frame Replacement (Non-Fold Flat)
Front Seat Back Frame Replacement (Non-Fold Flat)
Removal Procedure
1. Remove the front seat from the vehicle. 2. Remove the seat back trim cover and pad. 3. If the
seat is equipped with lumbar support, perform the following procedure:
1. Adjust the knob until the lumbar basket is in the position of least support. 2. Pull back on the
lumbar cable sleeve. 3. Remove the barrel end of the cable from the lumbar actuator.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15573
Caution: The seat back frame springs are under tension. To avoid personal injury, use care when
removing or installing the frame.
4. From the rear of the seat, adjust the rear seat back until the notches in the seat back frame line
up with the hook end of the springs on the seat back
frame.
5. Using a pair of channel lock(R) pliers, slide the spring into the notches on both sides of the seat
back frame.
6. Adjust the seat back forward to ensure that the springs are fully seated in the notches.
7. Remove the recliner handle screw and spring. Remove the recliner handle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15574
8. Remove the nuts from the outboard seat back frame. 9. If equipped, remove the teardrop washer
bolt and washer.
10. Remove the nuts from the inboard seat back frame.
Important: To provide additional clearance, you may loosen, but do NOT remove, the bolts on the
rear seat cushion frame.
11. Remove the seat back frame from between the adjusters.
Installation Procedure
1. Position the seat back frame between the adjusters.
Assure that the locating triangles on the seat back frame are properly seated in the mating holes in
the adjusters.
Notice: Refer to Fastener Notice.
2. If you loosened the bolts on the rear seat cushion frame during removal, secure the bolts at this
time.
Tighten the bolts to 12 N.m (9 lb ft).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15575
3. Install the outboard teardrop washer and bolt.
Tighten the bolt to 35 N.m (26 lb ft).
4. Install the nut to the outboard seat back frame.
Tighten the nut to 17 N.m (13 lb ft).
5. Install the nuts to the inboard seat back frame.
Tighten the nuts to 17 N.m (13 lb ft).
Caution: The seat back frame springs are under tension. To avoid personal injury, use care when
removing or installing the frame.
6. Position the recliner handle and spring. Install the recliner handle bolt.
Tighten the bolt to 10 N.m (89 lb in).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15576
7. Adjust the seat back until the hook end of the springs are adjacent to the adjuster pins.
8. Using a pair of channel lock(R) pliers, slide the springs from the notches in the frame to the pin.
9. Adjust the seat back to ensure proper operation.
10. If the seat is equipped with lumbar support, perform the following procedure:
1. Pull back on the lumbar cable sleeve. 2. Install the barrel end of the cable from the lumbar
actuator. 3. Adjust the knob to ensure that the cable is properly installed.
11. Install the seat back trim cover and pad. 12. Install the front seat to the vehicle.
Rear Seat Recliner Replacement
Rear Seat Recliner Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15577
Rear Seat Back Cushion Cover and Pad Replacement
Rear Seat Back Cushion Cover and Pad Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15578
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15579
Rear Seat Back Cushion Frame Replacement
Rear Seat Back Cushion Frame Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15580
Rear Seat Back Cushion Latch Cable Replacement
Rear Seat Back Cushion Latch Cable Replacement
Removal Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15581
1. Remove the rear seat. 2. Remove the fastener from the rear seat back latch and pull the latch
out from the seat back assembly.
3. Detach the latch cable from the latch.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15582
4. If you are going to replace the cable, disconnect the latch cable at the seat recliner mechanism.
5. Open the J-strip at the bottom of the seat cover.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15583
6. Pull the cable out from the seat back assembly.
Installation Procedure
1. If you are replacing the cable, route the cable through the rear seat back.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15584
2. Connect the latch cable to the recliner mechanism.
3. Connect the J-strip at the bottom of the seat cover. 4. Connect the latch cable to the latch
assembly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement (Fold Flat) > Page 15585
Notice: Refer to Fastener Notice.
5. Install the latch to the seat back with a fastener.
Tighten the fastener to 2.5 N.m (22 lb in).
6. Install the rear seat.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Customer Interest: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose
Seat Cover: Customer Interest Interior - Seat Cushion Cover Loose
TECHNICAL
Bulletin No.: 06-08-50-005D
Date: July 23, 2010
Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings)
Models:
2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada
Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn
ION
Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard
Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories).
Condition
Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is
loose.
Cause
This condition may be caused by the J-strip seat cover retaining feature releasing from the seat
frame.
Correction
1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI.
Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009
Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step
2.)
2. Reattach the J-strip to the seat frame.
3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the
J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > Customer Interest: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page 15594
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info
Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info
INFORMATION
Bulletin No.: 04-08-50-006D
Date: September 09, 2010
Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and
Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and
Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin
Number 04-08-50-006C (Section 08 - Body and Accessories).
If a customer comes in to your dealership due to certain conditions of the seat covers (splits,
wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of
the customer claim. Some components from the above listed vehicles have been returned to the
Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or
No Trouble Found (NTF).
The dealer should pay particular attention to the following conditions:
- Cigarette burns
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info > Page 15600
- Customer induced cuts (knife cuts, cut by customer tools, etc.)
- Paint stains (customer should have cleaned paint stains while paint was still wet)
- Coffee stains and other removable dirt These should be cleaned as described in the Owner's
Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later.
- Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual
- Other chemical spills
- Minor and normal leather wrinkles as a result of use
- Other defects to the seat cover not detected during the pre-delivery inspection (PDI).
Inform the customer that the above issues were not present when the vehicle was purchased and
cannot be replaced under warranty. The covers, however, may be repaired or replaced at the
customer's expense.
The following conditions are not caused by the customer and should be covered by warranty:
- Split seams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info > Page 15601
- Wear/cracking/peeling
- Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed
after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409),
replace the covers.)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose
Seat Cover: All Technical Service Bulletins Interior - Seat Cushion Cover Loose
TECHNICAL
Bulletin No.: 06-08-50-005D
Date: July 23, 2010
Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings)
Models:
2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada
Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn
ION
Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard
Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories).
Condition
Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is
loose.
Cause
This condition may be caused by the J-strip seat cover retaining feature releasing from the seat
frame.
Correction
1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI.
Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009
Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step
2.)
2. Reattach the J-strip to the seat frame.
3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the
J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose
> Page 15606
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces
of Vehicle
Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle
INFORMATION
Bulletin No.: 06-00-89-029F
Date: April 27, 2010
Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather,
Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability
Models:
2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum
and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009
Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-00-89-029E (Section 00 - General Information).
To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the
upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which
can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care
should be taken because newspapers and garments may transfer color to the vehicle's interior.
Many of today's interiors are made with new low gloss materials. Permanent damage may result
from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and
fabric) for which they are not intended. Using non-approved products can actually set the stain to
the point that nothing can remove it.
Important
Do not use silicone or wax-based products or those containing organic solvents (such as naptha,
alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing
the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the
windshield and even make it difficult to see through the windshield under certain conditions.
- Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This
can cause damage to the vehicle's interior surfaces.
- Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt.
Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of
the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are
in the neutral-pH range and will maintain the best vehicle interior appearance. These products are
water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals.
Interior trim pieces on new vehicles, as well as service components, arrive with a protective film.
When removing the protective film, adhesive residue may be left on the trim panels/components.
The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing
adhesive residue without causing damage to the component.
Important
- If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the
residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the
pH neutral range, they won't leave behind soapy residue.
- On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be
treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this
bulletin for more information.
Effective cleaning steps for hard and/or plastic surfaces:
1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the
towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work
cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the
surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the
towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's
original luster.
Important Today's interiors are developed and intended to have a low-gloss appearance. It is
important to use only products which provide a low-gloss finish in order to maintain the interior's
integrity, customer appeal and satisfaction.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces
of Vehicle > Page 15611
Effective cleaning steps for fabric:
1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate
stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle
brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to
reduce or eliminate future staining.
Upholstery and Carpet Stains
When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you
determine which cleaner/formula works best on a particular stain. The chart lists many of the
common stains. Some complex stains may require the application of both stain removers, one after
the other, to remove both food-based oils and synthetic oils.
A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain
or material. This enables the dirt/stain to be completely removed from the material.
Leather Conditioner/Restorer
A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a
water-based product and contains essential emollients to restore suppleness, conditions and adds
luster without adding gloss. The restorer will also provide protection against re-staining.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces
of Vehicle > Page 15612
Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede
comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will
appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely
affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with
the restorer.
Extractor Machine and Concentrate
For difficult to clean materials or when cleaning a large area, the best results will be achieved when
using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N
627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released
a concentrate for use with the extractor machine.
Whichever extractor machine is used, it should meet the minimum specifications of the Ruby
Extractor:
Ruby Extractor Specifications:
- Pump PSI: 55
- Water Lift: 85"
- Hose Length: 10 ft
Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty.
Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in
the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The
water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry
time is greatly reduced due to less water on the fabric surface, the vacuum head making better
contact with the surface and the significant water lift capability of the machine.
Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help
remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions
listed on the container. The available concentrate helps to break the stain down and then the stain
is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to
remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions.
Dirt, grease and grime are more easily removed when the proper solution is used during the
extraction process.
Parts Information
Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles.
Available Equipment
Equipment is available by contacting 1-800-GMTOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces
of Vehicle > Page 15613
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors
Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors
INFORMATION
Bulletin No.: 00-00-89-027E
Date: September 29, 2008
Subject: Eliminating Unwanted Odors in Vehicles
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add model years and refine the instructions. Please discard
Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information).
Vehicle Odor Elimination
General Motors offers a product that may control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic,
biodegradable odor remover. This odorless product has been shown to greatly reduce or remove
objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer
created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl,
leather, carpet and sound deadening materials. It may also be induced into HVAC modules and
instrument panel ducts (for the control of non-bacterial related odors).
Important:
This product leaves no residual scent and should not be sold as or considered an air freshener.
Product action may result in the permanent elimination of an odor and may be preferable to
customers with allergies who are sensitive to perfumes.
How to Use This Product
GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam
cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all
vehicle interiors. Do not wet or soak any interior surface that plain water would cause to
deteriorate, as this product will have the same effect. Also avoid letting this product come into
contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of,
or render GM Vehicle Care Odor Eliminator inert.
Note:
Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a
replacement set faxed or e-mailed to your dealership.
Instructions and cautions are printed on the bottle, but additional help is available. If you encounter
a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada,
1-800-977-4145) to obtain additional information and usage suggestions.
Important:
This product may effectively remove odors when directly contacting the odor source. It should be
used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the
root cause of the odor, and then the residual odor to permanently correct the vehicle condition.
Vehicle Waterleak Odor Elimination
STEP ONE:
Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water
soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor
source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle
interior by careful evaluation. Odor evaluation may need to be performed by multiple persons.
Another method of isolating an odor source is to remove and segregate interior trim and
components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist
in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated
separately to determine if the odor stays with the vehicle or the interior components. Odors that
stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak
at the windshield or standing water in the front foot well area caused mold/mildew to form on the
bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and
primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and
dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product
before reinstalling carpet or reassembling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors > Page 15618
The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used
properly. It must come into direct contact with the odor source. It should be used in conjunction with
diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after
odor root cause correction are:
STEP TWO:
^ Use the trigger spray head.
^ Put a drop of dish soap the size of a quarter in the bottom of a bottle.
^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with
tap water.
^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan)
STEP THREE:
The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and
upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting
(at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The
headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and
upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should
be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface.
STEP FOUR: (vehicle ventilation system treatment)
The ventilation system is generally the last step in the treatment of the vehicle.
a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per
vent).
b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting).
c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of
windshield)
d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents.
e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into
the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell
coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray
3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7
minutes.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited
is resolved without completing every step, the remaining steps do not need to be performed. If
these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.
Additional Suggestions to Increase Customer Satisfaction
Here are some additional ideas to benefit your dealership and to generate greater customer
enthusiasm for this product.
^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to
your used car trades; treat loaner and demo cars during service and at final sale to eliminate
smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of
your normal vehicle detailing service.
^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle
purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM
Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the
vehicle. Customers may find this product can be used for a host of recreational activities
associated with their new vehicle, such as deodorizing a boat they tow, or a camper.
^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase
dealership traffic as these superior quality products cannot be purchased in stores. Many
Dealerships have product displays at the parts counter. Consider additional displays in the
Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many
customers who purchase vehicles and receive regular maintenance at your dealership may never
visit the parts counter, and subsequently are not exposed to the variety and value that these
products offer.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors > Page 15619
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info
Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info
INFORMATION
Bulletin No.: 04-08-50-006D
Date: September 09, 2010
Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and
Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and
Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin
Number 04-08-50-006C (Section 08 - Body and Accessories).
If a customer comes in to your dealership due to certain conditions of the seat covers (splits,
wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of
the customer claim. Some components from the above listed vehicles have been returned to the
Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or
No Trouble Found (NTF).
The dealer should pay particular attention to the following conditions:
- Cigarette burns
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info > Page 15625
- Customer induced cuts (knife cuts, cut by customer tools, etc.)
- Paint stains (customer should have cleaned paint stains while paint was still wet)
- Coffee stains and other removable dirt These should be cleaned as described in the Owner's
Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later.
- Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual
- Other chemical spills
- Minor and normal leather wrinkles as a result of use
- Other defects to the seat cover not detected during the pre-delivery inspection (PDI).
Inform the customer that the above issues were not present when the vehicle was purchased and
cannot be replaced under warranty. The covers, however, may be repaired or replaced at the
customer's expense.
The following conditions are not caused by the customer and should be covered by warranty:
- Split seams
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover
Wrinkle/Crease/Burn Info > Page 15626
- Wear/cracking/peeling
- Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed
after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409),
replace the covers.)
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of
Vehicle
Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle
INFORMATION
Bulletin No.: 06-00-89-029F
Date: April 27, 2010
Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather,
Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability
Models:
2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum
and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009
Saab 9-7X
Supercede: This bulletin is being revised to update the model years. Please discard Corporate
Bulletin Number 06-00-89-029E (Section 00 - General Information).
To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the
upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which
can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care
should be taken because newspapers and garments may transfer color to the vehicle's interior.
Many of today's interiors are made with new low gloss materials. Permanent damage may result
from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and
fabric) for which they are not intended. Using non-approved products can actually set the stain to
the point that nothing can remove it.
Important
Do not use silicone or wax-based products or those containing organic solvents (such as naptha,
alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing
the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the
windshield and even make it difficult to see through the windshield under certain conditions.
- Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This
can cause damage to the vehicle's interior surfaces.
- Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with
degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt.
Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of
the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are
in the neutral-pH range and will maintain the best vehicle interior appearance. These products are
water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals.
Interior trim pieces on new vehicles, as well as service components, arrive with a protective film.
When removing the protective film, adhesive residue may be left on the trim panels/components.
The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing
adhesive residue without causing damage to the component.
Important
- If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the
residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the
pH neutral range, they won't leave behind soapy residue.
- On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be
treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this
bulletin for more information.
Effective cleaning steps for hard and/or plastic surfaces:
1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the
towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work
cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the
surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the
towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's
original luster.
Important Today's interiors are developed and intended to have a low-gloss appearance. It is
important to use only products which provide a low-gloss finish in order to maintain the interior's
integrity, customer appeal and satisfaction.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of
Vehicle > Page 15631
Effective cleaning steps for fabric:
1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate
stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle
brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to
reduce or eliminate future staining.
Upholstery and Carpet Stains
When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you
determine which cleaner/formula works best on a particular stain. The chart lists many of the
common stains. Some complex stains may require the application of both stain removers, one after
the other, to remove both food-based oils and synthetic oils.
A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain
or material. This enables the dirt/stain to be completely removed from the material.
Leather Conditioner/Restorer
A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a
water-based product and contains essential emollients to restore suppleness, conditions and adds
luster without adding gloss. The restorer will also provide protection against re-staining.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of
Vehicle > Page 15632
Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede
comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will
appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely
affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with
the restorer.
Extractor Machine and Concentrate
For difficult to clean materials or when cleaning a large area, the best results will be achieved when
using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N
627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released
a concentrate for use with the extractor machine.
Whichever extractor machine is used, it should meet the minimum specifications of the Ruby
Extractor:
Ruby Extractor Specifications:
- Pump PSI: 55
- Water Lift: 85"
- Hose Length: 10 ft
Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty.
Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in
the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The
water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry
time is greatly reduced due to less water on the fabric surface, the vacuum head making better
contact with the surface and the significant water lift capability of the machine.
Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help
remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions
listed on the container. The available concentrate helps to break the stain down and then the stain
is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to
remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions.
Dirt, grease and grime are more easily removed when the proper solution is used during the
extraction process.
Parts Information
Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles.
Available Equipment
Equipment is available by contacting 1-800-GMTOOLS.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of
Vehicle > Page 15633
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors
Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors
INFORMATION
Bulletin No.: 00-00-89-027E
Date: September 29, 2008
Subject: Eliminating Unwanted Odors in Vehicles
Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior
HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X
Supercede:
This bulletin is being revised to add model years and refine the instructions. Please discard
Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information).
Vehicle Odor Elimination
General Motors offers a product that may control or eliminate odors in the interior and luggage
compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic,
biodegradable odor remover. This odorless product has been shown to greatly reduce or remove
objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer
created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl,
leather, carpet and sound deadening materials. It may also be induced into HVAC modules and
instrument panel ducts (for the control of non-bacterial related odors).
Important:
This product leaves no residual scent and should not be sold as or considered an air freshener.
Product action may result in the permanent elimination of an odor and may be preferable to
customers with allergies who are sensitive to perfumes.
How to Use This Product
GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam
cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all
vehicle interiors. Do not wet or soak any interior surface that plain water would cause to
deteriorate, as this product will have the same effect. Also avoid letting this product come into
contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of,
or render GM Vehicle Care Odor Eliminator inert.
Note:
Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor
Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by
step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a
replacement set faxed or e-mailed to your dealership.
Instructions and cautions are printed on the bottle, but additional help is available. If you encounter
a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada,
1-800-977-4145) to obtain additional information and usage suggestions.
Important:
This product may effectively remove odors when directly contacting the odor source. It should be
used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the
root cause of the odor, and then the residual odor to permanently correct the vehicle condition.
Vehicle Waterleak Odor Elimination
STEP ONE:
Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water
soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor
source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle
interior by careful evaluation. Odor evaluation may need to be performed by multiple persons.
Another method of isolating an odor source is to remove and segregate interior trim and
components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist
in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated
separately to determine if the odor stays with the vehicle or the interior components. Odors that
stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak
at the windshield or standing water in the front foot well area caused mold/mildew to form on the
bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and
primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and
dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product
before reinstalling carpet or reassembling.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors > Page 15638
The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used
properly. It must come into direct contact with the odor source. It should be used in conjunction with
diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after
odor root cause correction are:
STEP TWO:
^ Use the trigger spray head.
^ Put a drop of dish soap the size of a quarter in the bottom of a bottle.
^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with
tap water.
^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan)
STEP THREE:
The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and
upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting
(at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The
headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and
upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should
be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface.
STEP FOUR: (vehicle ventilation system treatment)
The ventilation system is generally the last step in the treatment of the vehicle.
a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per
vent).
b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting).
c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of
windshield)
d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents.
e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into
the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell
coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray
3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7
minutes.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited
is resolved without completing every step, the remaining steps do not need to be performed. If
these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.
Additional Suggestions to Increase Customer Satisfaction
Here are some additional ideas to benefit your dealership and to generate greater customer
enthusiasm for this product.
^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to
your used car trades; treat loaner and demo cars during service and at final sale to eliminate
smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of
your normal vehicle detailing service.
^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle
purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM
Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the
vehicle. Customers may find this product can be used for a host of recreational activities
associated with their new vehicle, such as deodorizing a boat they tow, or a camper.
^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase
dealership traffic as these superior quality products cannot be purchased in stores. Many
Dealerships have product displays at the parts counter. Consider additional displays in the
Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many
customers who purchase vehicles and receive regular maintenance at your dealership may never
visit the parts counter, and subsequently are not exposed to the variety and value that these
products offer.
Parts Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted
Odors > Page 15639
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > Customer Interest for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose
Seat Cushion: Customer Interest Interior - Seat Cushion Cover Loose
TECHNICAL
Bulletin No.: 06-08-50-005D
Date: July 23, 2010
Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings)
Models:
2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada
Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn
ION
Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard
Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories).
Condition
Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is
loose.
Cause
This condition may be caused by the J-strip seat cover retaining feature releasing from the seat
frame.
Correction
1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI.
Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009
Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step
2.)
2. Reattach the J-strip to the seat frame.
3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the
J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > Customer Interest for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover Loose > Page
15648
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover
Loose
Seat Cushion: All Technical Service Bulletins Interior - Seat Cushion Cover Loose
TECHNICAL
Bulletin No.: 06-08-50-005D
Date: July 23, 2010
Subject: Seat Cushion Cover Loose (Secure J-Strip to Seat Frame With Hog Rings)
Models:
2005-2009 Chevrolet Equinox 2005-2010 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada
Only) 2006-2009 Pontiac Torrent 2007-2010 Pontiac G5 2002-2009 Saturn VUE 2003-2007 Saturn
ION
Supercede: This bulletin is being updated to add the 2010 Cobalt and G5 models. Please discard
Corporate Bulletin Number 06-08-50-005C (Section 08 - Body & Accessories).
Condition
Some customers may comment that the seat cushion cover (cover on the lower part of the seat) is
loose.
Cause
This condition may be caused by the J-strip seat cover retaining feature releasing from the seat
frame.
Correction
1. Remove the seat from the vehicle, if necessary. Refer to Seat Replacement - Front Bucket in SI.
Tip The seats do not have to be removed on 2008-2009 Saturn VUE models. (For 2008-2009
Saturn VUE models, the tray under the passenger seat should be removed prior to performing Step
2.)
2. Reattach the J-strip to the seat frame.
3. Secure the J-strip to the seat frame with hog rings. Snap the hog rings through each end of the
J-strip and around the seat frame. 4. Reinstall the seat to the vehicle. Refer to Seat Replacement Front Bucket in SI.
Warranty Information
For vehicles repaired under warranty, use the table.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Seat Cushion: > 06-08-50-005D > Jul > 10 > Interior - Seat Cushion Cover
Loose > Page 15654
Disclaimer
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Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement
Seat Cushion: Service and Repair Front Seat Cushion Frame Replacement
Front Seat Cushion Frame Replacement
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Front Seat Cushion Frame Replacement > Page 15657
Seat Cushion: Service and Repair Front Seat Cushion Cover and Pad Replacement
Front Seat Cushion Cover and Pad Replacement
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Front Seat Cushion Frame Replacement > Page 15658
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Front Seat Cushion Frame Replacement > Page 15659
Seat Cushion: Service and Repair Front Seat Cushion Inner Trim Panel Replacement (Non-Fold
Flat)
Front Seat Cushion Inner Trim Panel Replacement (Non-Fold Flat)
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Front Seat Cushion Frame Replacement > Page 15660
Seat Cushion: Service and Repair Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)
Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)
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Front Seat Cushion Frame Replacement > Page 15661
Seat Cushion: Service and Repair
Front Seat Cushion Frame Replacement
Front Seat Cushion Frame Replacement
Front Seat Cushion Cover and Pad Replacement
Front Seat Cushion Cover and Pad Replacement
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Front Seat Cushion Frame Replacement > Page 15662
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Front Seat Cushion Frame Replacement > Page 15663
Front Seat Cushion Inner Trim Panel Replacement (Non-Fold Flat)
Front Seat Cushion Inner Trim Panel Replacement (Non-Fold Flat)
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Front Seat Cushion Frame Replacement > Page 15664
Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)
Front Seat Cushion Outer Trim Panel Replacement (Fold Flat)
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Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat Cushion Frame Replacement > Page 15665
Front Seat Cushion Outer Trim Panel Replacement (Non-Fold Flat)
Front Seat Cushion Outer Trim Panel Replacement (Non-Fold Flat)
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Front Seat Cushion Frame Replacement > Page 15666
Rear Seat Cushion Cover and Pad Replacement
Rear Seat Cushion Cover and Pad Replacement
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Front Seat Cushion Frame Replacement > Page 15667
Rear Seat Cushion Trim Panel Replacement
Rear Seat Cushion Trim Panel Replacement
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Front Seat Cushion Frame Replacement > Page 15668
Rear Seat Cushion Frame Replacement
Rear Seat Cushion Frame Replacement
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Front Seat Cushion Frame Replacement > Page 15669
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Specifications
Seat Heater: Specifications
Fastener Tightening Specifications
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Information and Instructions
Seat Heater: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Seat Heater: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 15764
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15765
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15766
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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Information and Instructions > Page 15767
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15768
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Information and Instructions > Page 15769
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15770
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Information and Instructions > Page 15771
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Information and Instructions > Page 15772
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15773
Seat Heater: Connector Views
Component Connector End Views
Heated Seat Element - Driver Back
Heated Seat Element - Driver Cushion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 15774
Heated Seat Element - Front Passenger Back
Heated Seat Element - Front Passenger Cushion
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15776
Seat Heater: Description and Operation
Heated Seats Description and Operation
The front heated seat system consists of the following components.
* Left heated seat switch
* Right heated seat switch
* Heated seat module
* Left seat cushion heater element
* Left seat back heater element
* Left seat temperature sensor
* Right seat cushion heater element
* Right seat back heater element
* Right seat temperature sensor
* Climate Control Panel (CCP)
* HTD/SEAT 10 A
Power and Ground
Battery positive voltage is supplied at all times to the heated seat module from the HTD/SEAT fuse
located in the I/P fuse block. This voltage is used by the module to supply power to the seat
heating elements. The module is grounded through the module ground circuit and G301.
Heated Seat Operation
The driver and passenger heated seats are controlled by a single heated seat module that is
located under the driver seat cushion. Both heated seats are controlled by separate heated seat
switches that are located in the climate control panel (CCP). When a heated seat switch is pressed,
the CCP sends a GMLAN message via the serial data line to the heated seat module indicating the
heated seat command. In response to this signal, the heated seat module then applies battery
positive voltage through the element supply voltage circuit to the appropriate seat heating
elements. The heated seat module then sends a GMLAN message back to the CCP to either
illuminate or turn off the appropriate temperature indicator.
Temperature Regulation
When the ignition is turned to the ON position, the heated seats will initialize in the OFF state. With
each activation of the heated seat switch, the heated seat module will cycle the temperature setting
in the following manner: HIGH, LOW, and OFF.
The heated seat system is designed in order to warm the seat cushion and seat back to
approximately 42°C (107.6°F) when in the high heat position, and 37°C (98.6°F) when in the low
heat position. The heated seat module monitors the seat temperature through the temperature
sensor signal circuit and the temperature sensor (thermistor) that is located in the seat cushion.
The temperature sensor is a variable resistor, it's resistance changes as the temperature of the
seat changes. When the temperature sensor resistance indicates to the heated seat module that
the seat has reached the desired temperature, the module opens the ground path of the seat
heating elements through the heated seat element control circuit. The module will then cycle the
element control circuit open and closed in order to maintain the desired temperature.
Load Management
The load-shed operation is a means of reducing vehicle electrical loads during a low voltage or low
battery state of charge (SOC) condition. During certain load-shed conditions, all heated seat
functions will be disabled. Refer to Electrical Power Management Description and Operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview
Seat Heater: Initial Inspection and Diagnostic Overview
Diagnostic Starting Point - Seats
Always begin the diagnosis by reviewing the system Description and Operation. Reviewing the
Description and Operation will help you determine the correct symptom diagnostic procedure when
a malfunction exists. Reviewing the Description and Operation will also help you determine if the
condition described by the customer is normal operation.
Begin diagnosis with the Diagnostic System Check - Vehicle. The Diagnostic System Check will
provide the following information:
* The identification of the control modules which command the system
* The ability of the control modules to communicate through the serial data circuit
* The identification of any stored diagnostic trouble codes and their status See: Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
The use of the Diagnostic System Check will identify the correct procedure for diagnosing the
system and where the procedure is located.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 15779
Seat Heater: Symptom Related Diagnostic Procedures
Symptoms - Seat Heating and Cooling
Symptoms - Seat Heating and Cooling
Important: The following steps must be completed before using the symptom tables.
1. When diagnosing a heated seat system condition perform the Diagnostic System Check Vehicle, before using the symptom tables in order to
verify that all of the following are true:
* There are no DTCs set.
* The control module(s) can communicate via the serial data link. See: Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle
2. Review the system operation in order to familiarize yourself with the system functions. Refer to
Heated Seats Description and Operation.
Visual/Physical Inspection
* Inspect for aftermarket devices which could affect the operation of the power seats.
* Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
* Inspect the seat adjuster track for conditions which may cause binding or objects within the seat
adjustment range which obstruct movement or interfere with wiring.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing
for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests
and General Diagnostics
Symptom List
Refer to the Heated Seat Inoperative diagnostic procedure in order to diagnose the symptom.
Heated Seat Inoperative
Heated Seat Inoperative
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The driver and front passenger heated seats are controlled by separate heated seat switches. Both
switches are located in the climate control panel (CCP). When a heated seat switch is pressed, the
CCP sends a GMLAN message via the serial data line to the heated seat module indicating the
heated seat request. In response to this signal, the heated seat module activates the heated seat
by applying battery voltage to the seat heating elements. The heated seat module then sends a
GMLAN message back to the CCP commanding it to illuminate the appropriate seat temperature
indicator.
Circuit/System Testing
Ignition ON, use a scan tool to observe the appropriate Heated Seat Switch parameter while
pressing the heated seat switch. The reading should change between Idle and Pressed.
If not, replace the HVAC control module. If the parameter displays Pressed, replace the heated
seat module.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat)
Seat Heater: Service and Repair Driver Seat and Passenger Seat Back Cushion Heater
Replacement (Non-Fold Flat)
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15782
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15783
Seat Heater: Service and Repair Driver Seat and Passenger Seat Back Cushion Heater
Replacement (Fold Flat)
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Fold Flat)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15784
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15785
Seat Heater: Service and Repair Driver Seat and Passenger Seat Cushion Heater Replacement
(With Passenger Presence System)
Driver Seat and Passenger Seat Cushion Heater Replacement (With Passenger Presence System)
Removal Procedure
1. Remove the front seat from the vehicle. 2. Place the seat on a clean work bench. 3. Remove the
seat cushion cover and pad. 4. Do not remove the original heater element from the seat foam,
damage could occur to the inflatable restraint passenger presence system (PPS) or
foam pad. If this is the second repair, separate and remove the service heater element from the
original element. No more than two heater elements can be stacked on top of the PPS at one time.
5. Cut the wiring harness off the old heater element flush to the element.
Installation Procedure
1. Peel off the self-stick tape from the back of the heater element.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15786
2. Position the heater element over the seat foam pad and align the tabs and holes of the heater
element to the seat foam. Press firmly to engage the
adhesive.
3. Route the heating element wiring harness under the seat pad and connect the harness to the
heater module. Secure the wire with tie straps. 4. Install the seat cushion cover and pad. 5. Install
the front seat to the vehicle.
Important: Perform the passenger presence system preload test procedure when performing any
repairs to the passenger seat.
6. Preload test the inflatable restraint passenger presence system for the front passenger seat.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15787
Seat Heater: Service and Repair Driver Seat and Passenger Seat Cushion Heater Replacement
(Without Passenger Presence System)
Driver Seat and Passenger Seat Cushion Heater Replacement (Without Passenger Presence
System)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair >
Driver Seat and Passenger Seat Back Cushion Heater Replacement (Non-Fold Flat) > Page 15788
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-001 > Feb > 10 > Electrical No Crank/Start Discharged or Low Battery
Seat Heater Control Module: Customer Interest Electrical - No Crank/Start Discharged or Low
Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-001 > Feb > 10 > Electrical No Crank/Start Discharged or Low Battery > Page 15797
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-001 > Feb > 10 >
Electrical - No Crank/Start Discharged or Low Battery
Seat Heater Control Module: All Technical Service Bulletins Electrical - No Crank/Start Discharged
or Low Battery
TECHNICAL
Bulletin No.: 10-08-50-001
Date: February 15, 2010
Subject: No Crank, No Start, Discharged or Low Battery (Reprogram Heated Seat Module)
Models:
2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2009 Pontiac Torrent Equipped
with Front Heated Seats
Condition
Some customers may comment on a no crank, no start, discharged or low battery.
Note
This condition may be intermittent, therefore it is important to check if a revised calibration has
been released on TIS2WEB for this concern, even if the condition cannot be duplicated at the
dealer.
Cause
This condition may be caused by the heated seat module discharging the battery. The module
keeps the serial data bus active, which creates a cumulative, continuous amperage draw on the
battery after the vehicle is shut down, until the state of charge reaches three volts.
Correction
Important DO NOT replace the heated seat module or the battery for this concern.
Reprogram the heated seat module with the latest software calibration.
Important Select the correct calibration files for the appropriate vehicle configuration (body style)
and RPO codes.
A revised calibration has been developed to address this condition. Technicians are to reprogram
the heated seat module using the Service Programming System (SPS) with the latest software
available on TIS2WEB. Refer to the Service Programming System (SPS) procedures in SI.
When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it
is updated with the latest software version.
During programming, the battery voltage must be maintained within the proper range of 12-15
Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming
Support Tool EL-49642) or equivalent during programming.
Warranty Information
For vehicles repaired under warranty, use the table above.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-001 > Feb > 10 >
Electrical - No Crank/Start Discharged or Low Battery > Page 15803
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15804
Seat Heater Control Module: Locations
Passenger Compartment/Roof Component Views
Manual Passenger Seat Components
1 - Inflatable Restraint Passenger Presence (PPS) Sensor 2 - Seat Frame 3 - Heated Seat Element
- Front Passenger Back (KA1) 4 - Seat Belt Switch - Passenger 5 - Heated Seat Element - Front
Passenger Cushion (KA1) 6 - Heated Seat Control Module (KA1) 7 - Inflatable Restraint Passenger
Presence (PPS) Module
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15805
Seat Heater Control Module: Diagrams
Component Connector End Views
Heated Seat Control Module X1 (KA1)
Heated Seat Control Module X2 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15806
Heated Seat Control Module X3 (KA1)
Heated Seat Control Module X4 (KA1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15807
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15808
Seat Heater Control Module: Service and Repair
Front Seat Heater Control Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Technical Service Bulletins > Page 15809
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations
Seat Heater Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations >
Page 15813
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Diagrams
Hood Sensor/Switch (For Alarm): Diagrams
Component Connector End Views
Hood Ajar Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor >
Component Information > Locations
Pedal Positioning Sensor: Locations
Instrument Panel/Center Console Component Views
Pedal Assembly Components
1 - Brake Pedal Position Sensor 2 - Accelerator Pedal Position (APP) Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor >
Component Information > Locations > Page 15822
Pedal Positioning Sensor: Diagrams
Component Connector End Views
Brake Pedal Position Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations
Power Door Lock Switch: Locations
Door Component Views
Driver Door Components
1 - Outside Rearview Mirror - Driver 2 - Window Motor - Driver 3 - Door Lock Switch - Driver 4 Door Latch - Driver
Passenger Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 15826
1 - Door Latch - Front Passenger 2 - Door Lock Switch - Front Passenger 3 - Window Motor - Front
Passenger 4 - Outside Rearview Mirror - Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 15827
Power Door Lock Switch: Diagrams
Component Connector End Views
Door Lock Switch - Driver
Door Lock Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 15828
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 15829
Power Door Lock Switch: Service and Repair
Door Lock Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Power Mirror Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 15833
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 15834
Power Mirror Switch: Diagrams
Component Connector End Views - Continued
Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 15835
Power Mirror Switch: Service and Repair
Power Mirror Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views
Power Seat Switch: Locations Passenger Compartment/Roof Component Views
Passenger Compartment/Roof Component Views
Power Driver Seat Components
1 - Seat Belt Switch - Driver 2 - Seat Horizontal Motor - Driver (AG1) 3 - Heated Seat Element Driver Cushion (KA1) 4 - Heated Seat Element - Driver Back (KA1) 5 - Seat Adjuster Switch Driver (AG1) 6 - Seat Rear Vertical Motor - Driver (AG1) 7 - Seat Front Vertical Motor - Driver
(AG1)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 15840
Power Seat Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Passenger Compartment/Roof Component Views > Page 15841
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 15842
Power Seat Switch: Diagrams
Component Connector End Views - Continued
Seat Adjuster Switch Driver
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Power Seat Switch: Service and Repair Driver Seat and Passenger Seat Adjuster Switch Knob
Replacement
Driver Seat and Passenger Seat Adjuster Switch Knob Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement >
Page 15845
Power Seat Switch: Service and Repair Power Seat Switch Replacement
Power Seat Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Driver Seat and Passenger Seat Adjuster Switch Knob Replacement >
Page 15846
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
Seat Heater Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 15850
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
Sunroof / Moonroof Switch: Locations
Passenger Compartment/Roof Component Views
Front Headliner Components
1 - Dome Lamp - Center (-UUC) 2 - Cellular Telephone Microphone (UE1) 3 - Sunroof Switch
(CF5) 4 - Courtesy / Map Lamp
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 15854
Sunroof / Moonroof Switch: Diagrams
Component Connector End Views - Continued
Sunroof Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 15855
Sunroof / Moonroof Switch: Service and Repair
Sunroof Switch Replacement
Removal Procedure
1. Pull gently at front of reading lamp cover to disengage retaining clips. 2. Rotate cover rearward
until rear attaching hooks are released. 3. Disconnect sunroof switch harness from sunroof switch.
4. Remove sunroof switch fasteners and remove sunroof switch.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 15856
1. Install sunroof switch with fasteners.
Tighten sunroof switch to 2.5 N.m (22 lb in)
2. Connect sunroof switch harness to sunroof switch. 3. Position front reading lamp cover into rear
attaching hooks. 4. Rotate front reading lamp cover into lamp assembly forward, then snap cover
into place. 5. Function sunroof switch to ensure proper operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Trunk / Liftgate Switch: Diagrams
Component Connector End Views - Continued
Liftgate Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Service and
Repair
Sound Proofing / Insulation: Service and Repair
Front Fender Insulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair
Splash Guard: Service and Repair
Engine Splash Shield Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information >
Service and Repair
Spoiler: Service and Repair
Rear Spoiler Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide
Front Strut / Shock Tower: Customer Interest Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15879
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15880
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15881
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15882
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > Customer Interest for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15883
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide
Front Strut / Shock Tower: All Technical Service Bulletins Body - General Water Leak Diagnostic
Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15889
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15890
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15891
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15892
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15893
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15894
Front Strut / Shock Tower: By Symptom
Technical Service Bulletin # 08-08-57-001A Date: 081008
Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15895
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15896
Water may be entering between the liftgate and the weatherstrip.
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15897
Condition 6
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15898
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15899
Parts Information
Disclaimer
Technical Service Bulletin # 08-08-57-001A Date: 081008
Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15900
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15901
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15902
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15903
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Front Strut / Shock Tower > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Front Strut / Shock Tower: > Page 15904
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Service and Repair
Front Door Weatherstrip: Service and Repair
Front Door Opening Weatherstrip Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service
and Repair > Hood Rear Outer Seal Replacement
Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement
Hood Rear Outer Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service
and Repair > Hood Rear Outer Seal Replacement > Page 15913
Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement
Hood Rear Seal Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information >
Service and Repair
Rear Door Weatherstrip: Service and Repair
Rear Door Opening Weatherstrip Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide
Trunk / Liftgate Weatherstrip: Customer Interest Body - General Water Leak Diagnostic Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15925
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15926
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15927
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15928
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 > Body General Water Leak Diagnostic Guide > Page 15929
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide
Trunk / Liftgate Weatherstrip: All Technical Service Bulletins Body - General Water Leak Diagnostic
Guide
TECHNICAL
Bulletin No.: 08-08-57-001A
Date: October 08, 2008
Subject: General Waterleak Diagnostic Guide
Models: 2005-2009 Chevrolet Equinox LS, LT 2006-2009 Pontiac Torrent LS, LT
Supercede:
This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate
Bulletin Number 08-08-57-001 (Section 08 - Body and Accessories).
Condition 1
Water may be entering from the top of the strut tower into the driver side and or passenger side
floor. Pull the carpeting back and check for water entering the vehicle.
Cause
Insufficient body sealer may be the cause.
Correction
Reseal the strut tower. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 2
Water may be entering through the seams in the floor pan on the driver side and/or passenger
side.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15935
Cause
Insufficient body sealer may be the cause.
Correction
Remove the carpet and reseal the sheet metal seam.
Condition 3
Water may be entering through the liftgate weatherstrip (between a gap in the sheet metal at the
bottom).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the weatherstrip and reseal the sheet metal.
Condition 4
Water may be entering between the liftgate and the weatherstrip.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15936
Cause
The liftgate may not be tight enough to the weatherstrip.
Correction
Adjust the liftgate. Refer to Liftgate Adjustment in SI.
Condition 5
Water may be entering through a gap in the sealer at the rear D-pillar (roof to body).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the roof rack and inspect for any voids in the sealant. Refer to Luggage Carrier
Replacement Equinox or Torrent in SI. Use 3M(TM) Ultrapro Autobody Sealant Clear or equivalent.
Condition 6
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15937
Water in spare tire compartment. Water may be entering through a gap in the sealer behind the
rear fascia (left or right side).
Cause
Insufficient body sealer may be the cause.
Correction
Remove the rear fascia and reseal the sheet metal seam. Refer to Rear Bumper Fascia
Replacement in SI.
Condition 7
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15938
Water in the rear compartment. Water may be entering through a gap in the sheet metal behind the
tail lamps.
Cause
Insufficient body sealer may be the cause.
Correction
Remove the tail lamps. Refer to Tail Lamp Replacement in SI and reseal the sheet metal seam.
Important:
IF A MILDEW ODOR IS PRESENT IN THE VEHICLE, REFER TO PIT4535.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 08-08-57-001A > Oct > 08 >
Body - General Water Leak Diagnostic Guide > Page 15939
Parts Information
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Page 15940
Trunk / Liftgate Weatherstrip: Service and Repair
Liftgate Wedge Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Adjustments
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
Notice: Improper cruise control release switch adjustment may cause brake damage such as brake
drag, heat buildup and excessive brake lining wear.
3. Disconnect the cruise brake switch harness connector. 4. Rotate the cruise brake switch
counterclockwise and remove the cruise brake switch from the switch retainer.
Important: Do not depress the brake pedal assembly during the brake switch installation.
Depressing the brake pedal will cause a brake drag condition.
5. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Adjustments > Page
15945
6. Connect the cruise brake switch harness connector. 7. Install the knee bolster. 8. Install the
instrument panel left lower closeout panel. 9. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Adjustments > Page
15946
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
3. Disconnect the cruise brake switch connector.
4. Rotate the cruise brake switch counterclockwise and remove the cruise brake switch from the
switch retainer.
Important: Depressing the brake pedal will allow easier access of the retainer locking tabs.
5. Gently compress the locking tabs on the cruise brake retainer and remove the switch retainer
from the brake pedal assembly.
Installation Procedure
Important: Ensure that the indexing arrow is facing to the right and the ears on the retainer are fully
extended on the back side of the bracket to prevent the retainer from being pushed out.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Adjustments > Page
15947
1. Install the cruise brake switch retainer into the upper hole of the brake pedal assembly with the
retainer arrow pointing in the 3 o'clock position.
Important: Do not depress the brake pedal assembly during the cruise brake switch installation.
Depressing the brake pedal during the cruise brake switch installation will cause a brake drag
condition.
2. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Adjustments > Page
15948
3. Connect the cruise brake switch harness connector. 4. Install the knee bolster. 5. Install the
instrument panel left lower closeout panel. 6. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments
Cruise Control Switch: Adjustments
Cruise Release Switch Adjustment
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
Notice: Improper cruise control release switch adjustment may cause brake damage such as brake
drag, heat buildup and excessive brake lining wear.
3. Disconnect the cruise brake switch harness connector. 4. Rotate the cruise brake switch
counterclockwise and remove the cruise brake switch from the switch retainer.
Important: Do not depress the brake pedal assembly during the brake switch installation.
Depressing the brake pedal will cause a brake drag condition.
5. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 15953
6. Connect the cruise brake switch harness connector. 7. Install the knee bolster. 8. Install the
instrument panel left lower closeout panel. 9. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 15954
Cruise Control Switch: Service and Repair
Cruise Control Release Switch Replacement
Removal Procedure
1. Remove the instrument panel left lower closeout panel. 2. Remove the knee bolster.
3. Disconnect the cruise brake switch connector.
4. Rotate the cruise brake switch counterclockwise and remove the cruise brake switch from the
switch retainer.
Important: Depressing the brake pedal will allow easier access of the retainer locking tabs.
5. Gently compress the locking tabs on the cruise brake retainer and remove the switch retainer
from the brake pedal assembly.
Installation Procedure
Important: Ensure that the indexing arrow is facing to the right and the ears on the retainer are fully
extended on the back side of the bracket to prevent the retainer from being pushed out.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 15955
1. Install the cruise brake switch retainer into the upper hole of the brake pedal assembly with the
retainer arrow pointing in the 3 o'clock position.
Important: Do not depress the brake pedal assembly during the cruise brake switch installation.
Depressing the brake pedal during the cruise brake switch installation will cause a brake drag
condition.
2. Install the cruise brake switch.
* Position the switch into the retainer with the electrical connector index notch pointing to the 1
o'clock position.
* Slide the switch in the retainer until the plunger is fully depressed into the barrel.
* Rotate the switch clockwise until the travel stop has been reached, approximately 60 degrees.
* Inspect the cruise brake switch to ensure the switch is properly locked into the switch retainer with
the cruise brake switch electrical connector index notch pointing to the 3 o'clock position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Adjustments > Page 15956
3. Connect the cruise brake switch harness connector. 4. Install the knee bolster. 5. Install the
instrument panel left lower closeout panel. 6. Use the scan tool to monitor CRUISE BRAKE
SWITCH in the engine control module (ECM) General Information data table, while depressing
and releasing the brake pedal. Verify the APPLIED and RELEASED states read correctly.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 15962
Cigarette Lighter: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 15963
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 15964
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 16006
4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16054
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16055
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16056
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16057
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16058
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16059
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Diagram Information and Instructions > Page 16060
Cigarette Lighter: Connector Views
Component Connector End Views
Cigar Lighter
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Page 16061
Cigarette Lighter: Service and Repair
Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement
Tools Required
J 42059 Cigar Lighter Socket Remover
Removal Procedure
1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle:
1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the
front of the receptacle. The J 42059 pushes the
plastic latches from these tab windows and the receptacle can be pulled straight out.
2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit
straight into the receptacle. Angle the J 42059
slightly for insertion into the receptacle.
3. Insert the other side of the "T" into the opposite tab window.
You must move the J 42059 handle toward horizontal to engage the other tab window.
4. Use the J 42059 to pull the receptacle straight out.
3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate
method:
1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in
the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component
Information > Diagrams > Page 16062
1. Route the connector through the retainer. Align the accessory power receptacle retainer to the
slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the
electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer.
Install the accessory power receptacle by pressing into place until fully seated. 5. Install the
accessory power receptacle fuse.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Description and Operation
Compass: Description and Operation
Compass Calibration and Magnetic Variance
Compass Magnetic Variation Adjustment
Compass variance is the difference between the earth's magnetic north and true geographic north.
If not adjusted to account for compass variance, the compass in the vehicle could give false
readings. Under certain circumstances, such as during a long distance cross-country trip, it will be
necessary to compensate for compass variance and reset the zone through the DIC.
World Magnetic Variation Map
1. Locate your geographic location. 2. Turn ON the ignition with the engine OFF. 3. Press the
vehicle information button until PRESS TO CHANGE COMPASS ZONE displays on the DIC. 4.
Press the set/reset button to scroll through and select the appropriate variance zone. 5. Navigate to
one of the trip/fuel menu screens to view the direction the vehicle is moving. This will be shown in
the bottom line and center of the
DIC display.
Compass Calibration
The compass direction will show CAL or C if it needs to be calibrated. Before calibrating the
compass, drive the vehicle to an area that is magnetically clean (free of large metallic objects).
1. Turn ON the ignition. 2. Before calibrating the compass, make sure the compass is set to the
variance zone in which the vehicle is travelling. See Compass Magnetic
Variation Adjustment below.
3. Press the vehicle information button until the PRESS TO CALIBRATE COMPASS screen is
displayed. 4. Press the set/reset button to start the compass calibration. 5. The DIC will display
CALIBRATING: DRIVE IN CIRCLES. Drive the vehicle in circles at less than 8 km/h (5 mph) to
complete the calibration.
The DIC will display CALIBRATION COMPLETE when the calibration is complete.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Description and Operation > Page 16066
Compass: Service and Repair
Electronic Compass Module Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Page 16071
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations
Dimmer Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Page 16075
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Page 16076
Dimmer Switch: Diagrams
Component Connector End Views
Dimmer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component
Information > Locations > Page 16077
Dimmer Switch: Service and Repair
Instrument Panel Lamp Dimmer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Description and Operation
Door/Trunk Ajar Indicator/Lamp: Description and Operation
Door Ajar Indicator Description and Operation
Door Ajar Indicator System Components
The door ajar indicator system consists of the following components:
* The body control module (BCM)
* The instrument panel cluster (IPC)
* The driver information center (DIC)
* The driver door jamb switch
* The passenger door jamb switch
* The left rear door jamb switch
* The right rear door jamb switch
* The liftgate actuator/ajar switch
Driver and Passenger Door Ajar Operation
The body control module (BCM) receives a discrete input from the respective jamb switch to
indicate the status of the door. The BCM then communicates this status to the instrument panel
cluster (IPC) via a class 2 message. The IPC, upon receipt of this class 2 message, will illuminate
the appropriate ajar message in the driver information center (DIC) and also send a class 2
message to the radio to activate the door ajar audible warning when the following conditions are
met:
* The transmission is removed from PARK.
* The vehicle speed is greater then 8.05 km/h (5 mph).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
Driver/Vehicle Information Display: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16084
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16085
Driver/Vehicle Information Display: Diagrams
Component Connector End Views
Driver Information Center (DIC) Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16086
Driver/Vehicle Information Display: Description and Operation
Driver Information Center (DIC) Description and Operation
The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If
enabled through Personalization, the DIC returns to the last display status before no power
condition.
There are 7 switch functions for the DIC.
* Trip/Fuel Switch
* Vehicle Information Switch
* Personalization Switch
* Set/Reset Switch
Trip/Fuel Information Switch
The trip/fuel button is used to navigate between fuel information and trip options. Cycle through the
following trip/fuel menus by successive pressing of the trip/fuel button.
* Average Fuel Economy (AFE)
* Average Vehicle Speed (AVE)
* Elapsed Time
* Fuel Range
* Fuel Used
* Odometer
* Outside Air Temperature
* Trip Timer
* Trip A
* Trip B
* Blank
Vehicle Information Switch
The driver information center (DIC) vehicle information switch is used to navigate between various
vehicle information. Cycle through the following vehicle information by successive pressing of the
vehicle information button.
* Blank Display
* Battery Voltage
* Compass Recalibration
* Compass Zone Setting
* Engine Oil Life Index
* English/Metric Units
* Front Tire Pressure
* Key Fob Programming Menu
* Oil Pressure
* Oil Temperature
* Rear Tire Pressure
* Tire Programming Menu
Personalization Switch
The personalization switch is used to navigate between vehicle personalization options. Cycle
through the following vehicle personalization options by successive pressing of the personalization
button.
* Approach Lighting
* Auto Lock
* Auto Unlock
* Chime Volume
* Delay Lock
* Display Language
* Exit Lighting
* Factory Settings
* Feature Settings
* Remote Lock
* Remote Unlock
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16087
* Remote Start
For more information on vehicle personalization features, refer to the Owner's Manual.
Set/Reset Switch
Press the set/reset button in order to set or acknowledge any switch menu options.
Average Fuel Economy
Average fuel economy is calculated using the equation: AFE = Distance/Fuel
* Distance = The accumulated distance travelled since the last reset of this value
* Fuel = The accumulated fuel consumption since the last reset of this value
The engine control module (ECM) sends the average fuel economy serial data message to the
instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be
changed between English units and metric units by selecting from the DIC trip/fuel information
switch.
Average Vehicle Speed
Average vehicle speed is calculated using the equation: Average Speed = AVS Distance/AVS Time
* Distance = The accumulated distance travelled since the last reset of this value
* Time = The accumulated time since the last reset of this value
Fuel Range
This message indicates the estimated distance that the vehicle can travel under the current fuel
economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is
calculated using the equation: Fuel Range = Range Distance/Range Fuel Used.
* Range Distance = The accumulated distance travelled since the last reset of this value.
* Range Fuel Used = The accumulated fuel delivered since the last reset of this value
The ECM sends the fuel range value to the IPC. IPC receives a serial data message with the fuel
information. The fuel range value is retained during ignition OFF and can be changed between
English and Metric units by accessing the DIC trip/fuel information switch. The Fuel Range display
cannot be reset. LOW is displayed when fuel range is below a predetermined value.
Fuel Used
This message indicates the amount of fuel used since last reset. Fuel Used is calculated using the
equation: Fuel Used = Fuel Sum.
* Fuel Used = The accumulated fuel used since the last reset of this value.
* Fuel Sum = The accumulated fuel sum since the last reset of this value
The ECM sends the fuel used value to the IPC. The IPC receives a serial data message with the
fuel information. The fuel used value is retained as long as battery power is available to the DIC.
The fuel used value can be changed between English and Metric units by accessing the DIC
trip/fuel information switch.
Elapsed Time
The timer records elapsed time starting from activation. When the DIC displays the timer, pressing
the DIC SET/RESET switch for 1 second resets the timer. Pressing the SET/RESET button on the
DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one
of the following formats:
The DIC displays the timer in the following format: XX: XX:XX:
The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third
XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59
seconds. After the maximum range is reached, the timer displays all zeros (00:00:00).
Battery Voltage
Battery voltage data is not determined by the DIC and is not a resettable parameter. The DIC
displays (- - -) when an invalid battery data is received or when the IPC experiences a loss serial
data communications.
Engine Oil Life Index
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16088
The Engine Oil Life Index displays the estimated percentage of oil life remaining. The engine
control module (ECM) sends the oil life remaining percentage to the instrument panel cluster (IPC)
via the serial data circuit. The driver information center (DIC) displays the current percentage of the
GM Oil Life System as determined by the ECM. When the engine oil life remaining percentage
drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON message. When the engine
oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting.
Tire Pressure Monitor
The instrument panel cluster (IPC) receives serial data messages from the tire pressure monitoring
(TPM) system for the front and rear tire pressure. The driver information center (DIC) displays the
pressure for each of the front and rear tires. Tire pressure values are not reset through the DIC.
Tire Programming Menu
The DIC displays the tire programming menu. The tire programming menu is used to initiate
programming of the tire pressure monitoring sensors. The DIC displays the tire programming menu
only when the vehicle is in PARK or NEUTRAL.
Compass Zone Setting
The DIC displays the compass zone information. The DIC display allows the user to change the
currently selected compass zone. Refer to Compass Calibration and Magnetic Variance.
Compass Recalibration
The DIC provides the display that allows the resetting of the currently stored compass calibrations
data and establish new calibration data. Refer to Compass Calibration and Magnetic Variance.
Key FOB Programming Menu
The key fob programming menu is used to initiate programming of the key fobs. The key fob
programming menu can only be achieved with the vehicle transmission in PARK. Refer to
Transmitter Programming for more information on compass zone setting.
English/Metric Button
The English/Metric button is used to toggle between English and Metric unit and can be accessed
through the DIC trip/fuel switch.
Trip A/B
The trip odometer A or B can be accessed through the DIC trip/fuel switch.
Language
The driver information center (DIC) is capable of displaying in the languages listed below.
However, the DIC is capable of storing at least 3 different languages at any one time.
* English
* French
* Spanish
A simultaneous press of the DIC Vehicle Information and Personalization Switches for about 1
second provides a shortcut to change the language without understanding the currently displayed
language. The Language settings may also be assessed through the DIC personalization switch.
Outside Air Temperature
The driver information center (DIC) displays the outside air temperature based on serial data
message from the HVAC controller. The outside air temperature can be displayed in English or
Metric Units. English or Metric Units can be selected from the DIC vehicle information menu. The
DIC displays (- - -) when an invalid outside air temperature is received or communication is lost
with the HVAC controller.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16089
Oil Pressure
The driver information center (DIC) displays the engine oil pressure as determined by the ECM.
The instrument panel cluster (IPC) receives a serial data message from the ECM indicating the
current engine oil pressure.
Oil Temperature
The driver information center (DIC) displays the engine oil temperature as determined by the ECM.
The instrument panel cluster (IPC) receives a serial data message from the ECM indicating the
current engine oil temperature.
Compass
The driver information center (DIC) displays the compass based on serial data message from the
BCM. The compass module communicates with the body control module (BCM) through a
bi-directional data circuit. The instrument panel cluster (IPC) receives compass information from
the BCM via the serial data circuit. The compass is displayed in the DIC with other vehicle
information and is centered at the bottom line of the DIC. The compass display is blank when a
malfunction is present with the compass module or a compass serial data communication fault
exists. The compass displays 'CAL' or 'C' when the compass needs to be calibrated or the
compass zone needs to be reset. Cycle the ignition before performing the compass magnetic
variation adjustment procedure. The DIC vehicle information switch allows the compass zone to be
reset or the compass calibrated.
Check that the compass module is properly installed in the vehicle since this may cause the
compass to malfunction. The embossed arrow on the compass module should be parallel to the
centerline of the vehicle.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 16090
Driver/Vehicle Information Display: Service and Repair
Driver Information Display Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16099
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16100
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16101
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16102
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16103
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender
Harness Modification > Page 16104
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16110
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16111
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16112
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16113
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16114
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 07290 > Jan > 08 >
Recall - Fuel Sender Harness Modification > Page 16115
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Page 16116
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air
Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
SIR Disabling and Enabling
SIR component location affects how a vehicle should be serviced. There are parts of the SIR
system installed in various locations around a vehicle. To find the location of the SIR components
refer to SIR Identification Views.
There are several reasons for disabling the SIR system, such as repairs to the SIR system or
servicing a component near or attached to an SIR component. There are several ways to disable
the SIR system depending on what type of service is being performed. The following information
covers the proper procedures for disabling/enabling the SIR system.
SIR Service Precautions
Caution: When performing service on or near the SIR components or the SIR wiring, the SIR
system must be disabled. Failure to observe the correct procedure could cause deployment of the
SIR components. Serious injury can occur. Failure to observe the correct procedure could also
result in unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags if the SDM loses battery
power during a collision. Deployment power is available for as much as 1 minute after
disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the
SIR system prevents deployment of the air bags from the reserved energy supply.
General Service Instructions
The following are general service instructions which must be followed in order to properly repair the
vehicle and return it to its original integrity:
* Do not expose inflator modules to temperatures above 65°C (150°F).
* Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
* Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:
* Inflatable restraint sensing and diagnostic module (SDM)
* Any Inflatable restraint air bag module
* Inflatable restraint steering wheel module coil
* Any Inflatable restraint sensor
* Inflatable restraint seat belt pretensioners
* Inflatable restraint Passenger Presence System (PPS) module or sensor
Disabling Procedure - Air Bag Fuse
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position.
Important: The SDM may have more than one fused power input. To ensure there is no unwanted
SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying
power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR
BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system
malfunction.
3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on
the system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Page 16121
Enabling Procedure - Air Bag Fuse
1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn
the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform
the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as
described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Disabling Procedure - Negative Battery Cable
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the
ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1
minute before working on system.
Enabling Procedure - Negative Battery Cable
1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3.
Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4.
Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate
as described. Refer to Diagnostic System
Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic
System Check - Vehicle
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument
Panel Control Module: > 08-08-49-017B > Apr > 09 > Instruments - Gauges Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier >
Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Instrument Panel Control Module: > 08-08-49-017B > Apr > 09 > Instruments - Gauges Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
16139
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
16140
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
16141
Customer TPMS Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
16142
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator >
Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page
16143
Frequently Asked Questions
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator
> Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR
If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON"
indicator. This indicator is not a maintenance indicator and does not mean a maintenance service
is required.
For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information
refer to Malfunction Indicator Lamp.
For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. See: Oil Change
Reminder Lamp/Service and Repair
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp >
Component Information > Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
Malfunction Indicator Lamp (MIL) Diagnosis
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module
(ECM) turns the MIL ON by grounding the MIL control circuit.
Circuit/System Verification
Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool.
Circuit/System Testing
1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated.
^ If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an
open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the
IPC.
2. Ignition OFF, disconnect connector X1 at the ECM. 3. Ignition ON, verify that the MIL is not
illuminated.
^ If the MIL is illuminated, inspect the MIL control circuit for a short to ground. If the circuit tests
normal, replace the IPC.
4. Ignition ON, verify that the MIL illuminates with a 3A fused jumper wire between the MIL control
circuit, ECM terminal X1-68, and ground.
^ If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high
resistance. If the circuit tests normal, replace the ECM.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Instrument Cluster Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide
Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide
INFORMATION
Bulletin No.: 07-08-49-020D
Date: December 06, 2010
Subject: IPC Odometer Programming Method Quick Reference Guide
Models:
2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3
2005-2009 Saab 9-7X
Attention:
This bulletin applies to vehicles sold in the U.S. and Canada Only.
Supercede: This bulletin is being revised to add information for the 2011 model year and add new
2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and
Accessories).
The purpose of this bulletin is to provide a reference guide to help identify which season odometer
programming method to use after replacing the instrument panel cluster (IPC). The three season
odometer programming methods in use today are listed below. In addition, this reference guide lists
the component where the season odometer value is stored. The season odometer value may be
stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM),
also commonly called a body control module (BCM).
Season Odometer Programming Methods in Use Today
1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup
at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2
is used to set up a replacement BCM, which includes loading the odometer value that is displayed
and stored in the IPC. A
replacement IPC will display the previously stored vehicle odometer value, communicated from the
BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as
part of the BCM programming procedure. It is not a stand-alone event.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16154
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16155
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 16156
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp >
Component Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
ENGINE OIL LIFE SYSTEM
WHEN TO CHANGE ENGINE OIL
Your vehicle has a computer system that lets you know when to change the engine oil and filter.
This is based on engine revolutions and engine temperature, and not on mileage. Based on driving
conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil
life system to work properly, you must reset the system every time the oil is changed.
When the system has calculated that oil life has been diminished, it will indicate that an oil change
is necessary. A "CHANGE ENGINE OIL SOON" message will come on. Change your oil as soon
as possible within the next 600 miles (1 000 km). It is possible that, if you are driving under the best
conditions, the oil life system may not indicate that an oil change is necessary for over a year.
However, your engine oil and filter must be changed at least once a year and at this time the
system must be reset. It is also important to check your oil regularly and keep it at the proper level.
If the system is ever reset accidentally, you must change your oil at 3,000 miles (5 000 km) since
your last oil change. Remember to reset the oil life system whenever the oil is changed.
HOW TO RESET THE ENGINE OIL LIFE SYSTEM
The Engine Oil Life System calculates when to change your engine oil and filter based on vehicle
use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is
required. If a situation occurs where you change your oil prior to a change engine oil light being
turned on, reset the system.
1. Turn the ignition key to "ON/RUN" with the engine off. 2. Fully press and release the accelerator
pedal three times within five seconds. The engine oil light will flash while the system is resetting. 3.
When the light stops flashing, turn the key to "LOCK/OFF".
If the change engine oil light comes back on and stays on when you start your vehicle, the engine
oil life system has not reset. Repeat the procedure.
WHAT TO DO WITH USED OIL
Used engine oil contains certain elements that may be unhealthy for your skin and could even
cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with
soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing
used engine oil. See the manufacturer's warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil
from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the
ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place
that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a
service station or a local recycling center for help.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Powertrain Component Views
Front Engine Components 1 of 2 (LNJ)
1 - Exhaust Gas Recirculation (EGR) Valve 2 - Throttle Actuator Control (TAC) Module 3 Evaporative Emissions (EVAP) Canister Purge Solenoid 4 - Transmission Control Module (TCM) 5
- Starter 6 - Starter Solenoid 7 - Engine Oil Pressure (EOP) Switch 8 - Knock Sensor (KS) 2 9 - A/C
Compressor Clutch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 16163
Oil Pressure Sender: Diagrams
Component Connector End Views
Engine Oil Pressure Switch (LNJ)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument
Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Instrument Panel Control Module: > 08-08-49-017B > Apr > 09 > Instruments - Gauges Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: Customer Interest Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument
Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Instrument Panel Control Module: > 08-08-49-017B > Apr > 09 > Instruments - Gauges
Inoperative/Erratic/Inaccurate
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Gauges
Inoperative/Erratic/Inaccurate
TECHNICAL
Bulletin No.: 08-08-49-017B
Date: April 20, 2009
Subject:
Instrument Panel Cluster (IPC) Gages Inoperative, Erratic/Inaccurate Gauge Readings (Reprogram
IPC)
Models:
2008 Buick Enclave 2008 Chevrolet Equinox, HHR, Malibu (excluding Malibu Classic) 2008 GMC
Acadia 2008 Pontiac Torrent 2008 Saturn AURA, OUTLOOK
Supercede: This bulletin is being revised to include the HHR models. Please discard Corporate
Bulletin Number 08-08-49-017A (Section 08 - Body and Accessories).
Condition
Some customers may comment that the instrument gages appear to be erratic/inaccurate or are
inoperative.
This condition may be intermittent and occur over one or multiple ignition cycles, eventually
resetting itself.
Cause
A software anomaly within the IPC allows the microprocessor to lose communication with the gage
temporarily.
Correction
A revised calibration has been developed to correct this condition. Technicians are to reprogram
the instrument panel cluster (IPC) using SPS with the latest software available on TIS2WEB. Refer
to the Service Programming System (SPS) procedures in SI. As always make sure your Tech 2(R)
is updated with the latest software version.
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations
Dimmer Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Page 16185
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Page 16186
Dimmer Switch: Diagrams
Component Connector End Views
Dimmer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Dimmer Switch > Component Information > Locations > Page 16187
Dimmer Switch: Service and Repair
Instrument Panel Lamp Dimmer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16196
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16197
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16198
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16199
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16200
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge Sender: >
07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16201
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification
Technical Service Bulletin # 07290 Date: 080117
Recall - Fuel Sender Harness Modification
Bulletin No.: 07290
Date: January 17, 2008
PRODUCT EMISSION
Subject: 07290 - Emission System - Incorrect Fuel Sender Harness Connector Plugs
Models: 2008 Chevrolet Equinox 2008 Pontiac Torrent
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2008 model
year Chevrolet Equinox and Pontiac Torrent vehicles. On these vehicles, there are two unused pin
cavities within the fuel sender wiring harness connector. To prevent moisture from entering the
harness, the unused pin cavities are filled with a plug. The plug used in these cavities may be
under-size and allow moisture to enter the harness.
Correction
Dealers are to inspect, and if necessary, install new plugs in the two unused cavities.
Vehicles Involved
Involved are certain 2008 model year Chevrolet Equinox and Pontiac Torrent vehicles built within
the VIN breakpoints shown.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry
System (GMVIS). Not all vehicles within the above breakpoints may be involved.
For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle
identification number, customer name, and address information has been prepared and will be
provided through the applicable system listed below. Dealers will not have a report available if they
have no involved vehicles currently assigned.
-- US dealers - GM DealerWorld Recall Information
-- Canadian dealers - GMinfoNet Recall Reports
-- Export dealers - sent directly to dealers
The listing may contain customer names and addresses obtained from Motor Vehicle Registration
Records. The use of such motor vehicle registration data for any purpose other than follow-up
necessary to complete this recall is a violation of law in several states/provinces/countries.
Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this
recall.
Parts Information
The plugs required to complete this recall are to be obtained from General Motors Service and
Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering
requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An
emergency requirement should be ordered on a CSO = Customer Special Order.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16207
The terminals listed in the chart shown may be required to perform the procedure in this bulletin
and are included in the J-38125 Terminal Repair Kit. Do not order this from GMSPO.
Service Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16208
Certain 2008 Chevrolet Equinox and Pontiac Torrent vehicles have smaller-than-specified
connector plugs installed in the 6th and 12th cavities of the fuel-sender harness 12-way connector
cavities. This condition may produce water corrosion in the 1st and 7th terminals. Refer to the
Fuel-Sender Wire Harness: Male and Female Connector Views information shown.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Locate the fuel-sender wire harness. The harness connector is located between the fuel tank and
rear floor pan of the vehicle.
Make sure you inspect the fuel tank or male side of the 12-pin electrical connector. The body or
female side of the 12-pin electrical connector is clipped to the vehicle chassis and will have green
plugs identified with short nipples (3). Do NOT remove the body or female side green plugs.
Inspect the fuel tank or male side of the black 12-pin body/fuel tank inline connector for
yellow-orange colored cavity plugs. These will be seen in cavities 6 and 12 of the connector (1).
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16209
If green cavity plugs with long nipples (2) are seen, proceed to step 4.
If yellow-orange cavity plugs are seen on the fuel tank side of the 12-pin electrical connector,
proceed to step 11.
Disconnect the black 12-pin body/fuel inline electrical connector.
Inspect the connector for bent or corroded terminals.
If there are bent or corroded terminals, refer to Step 6.
If there are NO bent or corroded terminals, refer to Step a.
Remove any bent or corroded pins from the connector.
Install the new terminals. Refer to the Parts Information section of this bulletin for terminal
information. Refer to Fuel-Sender Wire Harness:
Male and Female Connector Views in this bulletin and Repairing Connector Terminals in SI, if
required.
Remove green cavity plugs from the fuel tank or male side of the black 12-pin electrical connector.
Dry out connector with low air pressure.
Install new yellow-orange cavity plugs in cavities 6 and 12 of the fuel tank or male side of the black
12-pin body/fuel tank inline electrical connector.
Connect the black 12-pin body/fuel inline electrical connector.
Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:
Install a Recall Identification Label.
Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label (California/Connecticut/Massachusetts/Maine/Vermont Vehicles Only)
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions
outlined in this Product Recall Bulletin. Each label provides a space to include the recall number
and the five-digit dealer code of the dealer performing the recall service. This information may be
inserted with a typewriter or a ballpoint pen.
Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area
that will be visible to people servicing the vehicle.
When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear
protective covering. Additional Recall Identification Labels for US dealers can be obtained from
Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and
then click on the DWD Store link. Request Item Number S-1015 when ordering.
Courtesy Transportation - For US and Canada
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
Transportation guidelines.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16210
Claim Information
Customer Notification - For US and Canada
General Motors will notify customers of this recall on their vehicle (see copy of customer letter
shown in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Customer Notification - For Export
Letters will be sent to known owners of record located within areas covered by the US National
Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify
customers using the sample letter.
In order to ensure full protection under the emission warranty, and the right to participate in future
recalls, the customer notification letter recommends that customers have their vehicles serviced as
soon as possible. It also advises that failure to do so could legally be determined to be lack of
proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work
is not completed.
Dealer Recall Responsibility - All
All unsold new vehicles in dealers possession and subject to this recall must be held and
inspected/repaired per the service procedure of this recall bulletin before customers take
possession of these vehicles.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of
mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which
there is no customer information indicated on the dealer listing, are to be contacted by the dealer.
Arrangements are to be made to make the required correction according to the instructions
contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in
contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your
dealership for service in the future, you must take the steps necessary to be sure the recall
correction has been made before selling or releasing the vehicle.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT***
When a California emissions recall is completed by a GM dealer, the dealer must provide the
vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the
California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without
this correction certificate, the owner may be unable to renew their vehicle registration.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16211
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on
the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link.
Request GM Item Number 1825 when ordering.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Gauge Sender: > 07290 > Jan > 08 > Recall - Fuel Sender Harness Modification > Page 16212
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 16213
Fuel Gauge Sender: Diagrams
Component Connector End Views
Fuel Pump and Sender Assembly
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument
Panel > Parking Brake Warning Switch > Component Information > Service and Repair
Parking Brake Warning Switch: Service and Repair
Parking Brake Indicator Switch Replacement
Removal Procedure
1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
2. Remove the front floor console. Refer to Console Replacement . 3. Disconnect the warning lamp
switch electrical connector (2). 4. Remove the warning lamp switch mounting screw (1). 5. Remove
the switch from the park brake lever assembly.
Installation Procedure
1. Align the park brake warning lamp switch locating tab to the locating hole on the park brake lever
assembly. 2. Install the switch to the park brake lever.
Notice: Refer to Fastener Notice .
3. Install the park brake warning lamp switch mounting screw (1).
Tighten the screw to 4 N.m (35 lb in).
4. Connect the park brake warning lamp switch electrical connector (2). 5. Install the front floor
console. Refer to Console Replacement . 6. Enable the SIR system. Refer to SIR Disabling and
Enabling . 7. Verify correct park brake warning lamp operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips
Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System
Message/Service Tips
# 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive
for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010)
Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire
Pressure Monitor (TPM) System Message, Light and Customer Information
Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab)
2006-2010 HUMMER H2, H3
ATTENTION
The information found in this bulletin is to be used as a dealership service consultant procedures
for customers coming into the service lane with an illuminated "low tire light" or comments on a
check tire pressure/low tire pressure/add air to tire or service tire monitor system message.
Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under
warranty.
This bulletin is being revised to add model years and update additional bulletin reference
information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension).
Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System
The following procedure should be used by dealership service consultants when a customer comes
into the service drive with a "low tire light" on or comments on a check tire pressure/low tire
pressure/add air to tire or service tire monitor system message. The service consultant should
perform the following steps:
Procedure
Turn the key to ON, without starting the engine.
^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add
air to tire message (on vehicles equipped with DIC),
advise the customer:
- The system is working properly.
- Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn
the light off (refer to the Tire and Loading Information label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service
tire monitor system message (on vehicles equipped
with DIC):
- A TPM system problem exists. The vehicle should be written up accordingly and sent to your
service department for further DTC diagnosis and service.
- If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a
previous TPM system relearn that was performed incorrectly due to interference from another
vehicle's TPM system during the relearn process (refer to the Important statement later in this
bulletin regarding TPM relearn with a Tech 2(R)).
- If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem.
Follow the appropriate SI service procedures.
^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started,
then goes off after driving a while, advise the
customer:
- The system is working properly.
- Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires
are cold. After driving for a while, tires will heat
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 16222
up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly
adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and
Loading Information Label on the driver side door).
- More detailed information can be found in the Owner Manual.
- Service is not covered under warranty - this maintenance is the responsibility of the owner.
- Give the customer a copy of the "GM Customer TPMS Information".
For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS
Training Course 13044.12T2.
Tire Pressure Light
At key on, without starting the vehicle:
Steady Solid Glowing TPM Indicator
If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning
properly and you should add air to the tires to correct this condition.
Blinking TPM Indicator
If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid,
diagnostic service is needed.
The Effect of Outside Temperature on Tire Pressures
Important:
As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in
temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer.
Under certain situations such as extreme outside temperature changes, the system may bring on a
solid light with a check tire pressure message. This should be considered normal and the system is
working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the
Tire & Loading Information label in the driver's door opening). When properly adjusting tire air
pressure, the following steps are important to help optimize the system and prolong bringing a tire
pressure light on:
^ Use an accurate, high quality tire pressure gauge.
^ Never set the tire pressure below the specified placard value regardless of tire temperature or
ambient temperature.
^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature
the vehicle will encounter during operation.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 16223
^ When adding proper tire air pressure, it is important to remember fluctuations in outside air
temperatures and tire temperatures effect tire air pressures.
^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has
updated), check to see if DIC displays are the same
readings as the tire pressure gauge used (adjust as necessary).
^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the
Tech 2(R) to initiate the relearn whenever possible to
avoid invalid sensor I.D. learns.
Important:
Always take outside temperature and tire temperature into consideration to properly set tire
pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has
been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to
compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the
placecard pressure. At some later time, when the vehicle has been parked outside for a while, the
tires will cool off and the pressures will drop back into the placecard range.
Important:
Recently, nitrogen gas (for use in inflating tires) has become available to the general customer
through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile
racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to
outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For
additional information, refer to Corporate Service Bulletin 05-03-10-020C.
Important:
All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already
been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low
tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that
light turn back off again. Note that because of system behavior, some vehicles must be driven a
short distance before the sensors recognize the increase in pressure and turns the light off again.
Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update
and light will turn off when all tire pressures have been adjusted followed by short distance drive.
Important:
All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle
corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor
or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated
relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals
initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will
prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a
flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to
and following relearn to verify they are the same can prevent invalid I.D. learns.
Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not
perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during
pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been
adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079
tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech
2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech
2(R). Refer to SI for further Vibe TPMS information.
Labor Operation and Repair Order/Warranty System Claim Required Documentation
Important:
The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue.
That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM)
blinks for one minute and then stays on solid with a Service Tire Monitor System message (on
vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will
have set a DTC. If one of these operastions is used, the following Repair Order and Warranty
System documentation are required:
^ Document the customer complaint on the Repair Order.
^ Document the TPMS DTC that has set on the Repair Order.
^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim
submission (refer to the Claims Processing Manual,
Section IV, Warranty claim Data, Page 6, Item G).
If the above information is not documented on the Repair Order and Warranty System, the claim
may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order
documentation must be sent back.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 16224
Customer TPMS Information
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 16225
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire
Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System
Message/Service Tips > Page 16226
Frequently Asked Questions
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information
Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs
Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning
Sensor IDs
INFORMATION
Bulletin No.: 10-03-16-001
Date: July 19, 2010
Subject: TPMS System Service and Re-Learning Sensor IDs
Models:
2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and
Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted
Tire Pressure Sensors
In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM)
sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25
mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash
for approximately one minute and then remain on steady each time the ignition is turned ON,
indicating a diagnostic trouble code (DTC) has been set.
The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type
message. When the road tire is repaired and reinstalled in the original location, the TPM indicator
icon illumination and DIC message may remain displayed until the DTC is cleared.
To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to
clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn
procedure using a TPM diagnostic tool will provide the same results.
It is advised to perform the relearn procedure away from other vehicles to prevent picking up a
stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been
replaced, then the relearn procedure must be performed.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 16239
Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information
INFORMATION
Bulletin No.: 08-03-16-003
Date: May 12, 2008
Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to
Replacement Wheels and Allowable TPM Sensor Replacements
Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009
HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x
with On-Wheel TPM Sensors
TPM Sensor / Wheel Warranty Reviews
During the last warranty review period it was noted that wheels being returned under the GM New
Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to
the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM
sensors should not be returned to GM and are to be transferred to replacement wheels if they
become necessary.
Important:
Operational TPM Sensors that are returned under warranty to General Motors will be charged back
to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be
transferred if one or more wheels are replaced.
TPM Valve Stem / Grommet (0-ring) Replacement
When the TPM sensors are transferred to new wheels you should replace the component used to
seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the
outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The
sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except
Pontiac Vibe (4.0 N.m (35.4 lb in)).
Important:
^ DO NOT overtorque the retaining nut.
Notice:
^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps.
These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum
valve stems due to incompatibility of the metals.
On current style sensors the entire rubber stem is replaceable. The service interval on the revised
TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the
stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the
valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in).
For either style of TPM sensor see the service parts guide for the correct GM part numbers to order
and use.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 16240
Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors
INFORMATION
Bulletin No.: 08-03-10-007
Date: May 16, 2008
Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire
Mounting/Dismounting
Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and
Prior HUMMER H2, H3 2009 and Prior Saab 9-7X
with Wheel Mounted Tire Pressure Sensors
Minimizing Damage To TPM Sensors
All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada,
feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors.
When dismounting and mounting tires, care must be taken when breaking the bead loose from the
wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor,
as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire
pressure sensor. This can damage the sensor and require the sensor to be replaced.
Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the
tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in
contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head
prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement.
Procedure
Notice:
Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in
order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result.
Notice:
Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment.
Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Remove the valve core from the valve stem.
2. Deflate the tire completely.
Important:
Rim-clamp European-type tire changers are recommended.
3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the
tire from the wheel.
4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270
degrees from the valve stem.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 16241
5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the
head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the
mounting/dismounting head.
6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position
relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and
over the mounting/dismounting head.
7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire
sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure
sensor.
8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from
the wheel bead seats.
Important:
If bead seat corrosion has been identified as an air loss concern on the wheel being worked on,
refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak.
9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel
rim.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 16242
10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the
head (2). This will protect the sensor when the bottom bead seats.
12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is
situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting
the tire bead to the outside of the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning
Sensor IDs > Page 16243
13. Use the tire changer in order to install the tire to the wheel.
Caution:
To avoid serious personal injury, do not stand over tire when inflating. The bead may break when
the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any
tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate
the beads and reinflate. Overinflating may cause the bead to break and cause serious personal
injury.
Important:
Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires.
14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this
time.
15. Install the valve core to the valve core stem.
16. Inflate the tire to the proper air pressure.
17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire
bead is fully seated on the wheel.
Parts Information
The product shown above is available from GM SPO.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 16244
Tire Pressure Sensor: Service and Repair
Tire Pressure Indicator Sensor Replacement
Removal Procedure
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle . 2. Remove the
tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See:
Maintenance/Wheels and Tires/Service
and Repair) .
Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure
sensor damage upon tire dismounting.
* Place the sensor's cap and valve on a dry clean surface after removal. The cap is aluminum and
the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve
made of any other material.
*
When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from
the valve stem.
* Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly
clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting
head.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the out side of the wheel rim.
* Repeat items for inner bead.
3. Remove the tire from the wheel. Refer to Tire Mounting and Dismounting (See:
Maintenance/Wheels and Tires/Tires/Service and
Repair/Removal and Replacement) .
Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from
the inside of the tire and wheel surfaces.
4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor.
Installation Procedure
1. Clean any dirt or debris from the grommet sealing area.
2. Insert the sensor in the wheel hole with the air passage facing away from the wheel.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire
Pressure Sensor > Component Information > Technical Service Bulletins > Page 16245
Notice: Refer to Fastener Notice .
3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while
torquing.
Tighten the sensor nut to 7 N.m (62 lb in).
Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure
sensor damage upon tire mounting:
* Position the mounting/dismounting head 180 degrees from the valve stem.
* Position the bead transition area 45 degrees counterclockwise of the valve stem.
* Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead
to the inside of the wheel rim.
* Repeat items for outer bead.
4. Install the tire on the wheel. Refer to Tire Mounting and Dismounting (See: Maintenance/Wheels
and Tires/Tires/Service and Repair/Removal
and Replacement) .
Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the
sensor's unique identification code cannot be learned into the liftgate module (LGM) memory. The
sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20
mph) in order to close the sensor's internal roll switch for at least 10 seconds.
5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation
(See: Maintenance/Wheels and Tires/Service and
Repair) .
6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Sensor Learn
(Standard) (See: Service and Repair) .
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Service and Repair > Transmission Floor Shift Control Indicator Lamp Replacement
Transmission Shift Position Indicator Lamp: Service and Repair Transmission Floor Shift Control
Indicator Lamp Replacement
Transmission Floor Shift Control Indicator Lamp Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Service and Repair > Transmission Floor Shift Control Indicator Lamp Replacement >
Page 16250
Transmission Shift Position Indicator Lamp: Service and Repair AF33-5 - Automatic Transaxle
Automatic Transmission Control Indicator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Service and Repair > Transmission Floor Shift Control Indicator Lamp Replacement >
Page 16251
Transmission Shift Position Indicator Lamp: Service and Repair 6T70/6T75 - Automatic
Transmission
Automatic Transmission Control Indicator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations
Ambient Light Sensor: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
16256
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
16257
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page
16258
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information >
Locations
Backup Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information >
Service and Repair
Backup Light Bulb: Service and Repair
Backup Lamp Bulb Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Lighting - Exterior Lamp Condensation and Replacement
Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement
INFORMATION
Bulletin No.: 01-08-42-001H
Date: January 05, 2011
Subject: Exterior Lamp Condensation and Replacement Guidelines
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn)
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories).
The following information is being provided to better define the causes of condensation in exterior
lamps and includes guidelines for determining the difference between a lamp with a normal
atmospheric condition (condensation) and a lamp with a water leak.
Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit
very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens.
This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain
weather conditions.
Condensation occurs when the air inside the lamp assembly, through atmospheric changes,
reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly
condenses, creating a fine mist or white fog on the inside surface of the lamp lens.
Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable
bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it
through a vent system. The vent system operates at all times, however, it is most effective when
the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of
the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to
clear the lamp may vary from 2 to 6 hours.
Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of
models being manufactured today. These lamps require the replacement of the complete lamp
assembly if a bulb filament burns out.
Condensation 2006 TrailBlazer Shown
A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High
Humidity
- May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than
half the lens surface.
- The condition should clear of moisture when the vehicle is parked in a dry environment, or when
the vehicle is driven with the lights ON.
- A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR
performance.
If the above conditions are noted, the customer should be advised that replacement of a lamp
assembly may not correct this condition.
Water Leak New Style Pickup Shown
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Lighting - Exterior Lamp Condensation and Replacement > Page 16270
Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After
the Vehicle Has Been Exposed to Rain or a Car Washing Environment
- A condition that covers more than half the surface of the lamp lens.
- An accumulation of water in the bottom of the lamp assembly.
- A condition that WON'T clear when the vehicle is parked in a dry environment, or when the
vehicle is driven with the lights ON.
- A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different
performance.
Any of the above conditions would indicate the need to service the lens or lamp assembly.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Brake Lamp: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Brake Lamp: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Brake Lamp: Connector Views
Component Connector End Views - Continued
Park/Stop Lamp - Left Rear
Park/Stop Lamp - Right Rear
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Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair >
Brake Pedal Position Sensor Calibration
Brake Light Switch: Service and Repair Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Calibration
Calibration Criteria
The brake pedal position sensor (BPPS) receives a low reference signal and a 5-volt reference
signal from the BCM. Whenever the brake pedal is applied, the BPPS applies a variable voltage
signal to the BCM through the stop lamp switch signal circuit. The BPPS calibration must be
performed after the BPPS or body control module (BCM) have been serviced. The calibration
procedure will set BPPS home value. This value is used by the BCM to determine the action of the
driver applying the brake system and to provide this information to the vehicle subsystems via the
communication bus.
Calibration Procedure
* Install a scan tool.
* Turn ON the ignition, with the engine OFF.
* Select Diagnostics.
* Select the year.
* Select the vehicle type.
* Select BCM.
* Select Module Setup.
* Select the BPPS calibration procedure and follow the directions displayed on the screen.
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Brake Light Switch: Service and Repair Brake Pedal Position Sensor Replacement
Brake Pedal Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Cargo
Lamp Replacement
Cargo Lamp: Service and Repair Cargo Lamp Replacement
Cargo Lamp Replacement
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Cargo Lamp: Service and Repair Cargo Lamp Bulb Replacement
Cargo Lamp Bulb Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams
Center Mounted Brake Lamp: Diagrams
Component Connector End Views
Center High Mounted Stop Lamp (CHMSL)
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Center Mounted Brake Lamp: Service and Repair
High Mount Stop Lamp Replacement
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Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Courtesy Lamp: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Courtesy Lamp: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Courtesy Lamp: Connector Views
Component Connector End Views
Courtesy/Map Lamp
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams >
Diagram Information and Instructions
Daytime Running Lamp: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Daytime Running Lamp: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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Diagram Information and Instructions > Page 16546
5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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Diagram Information and Instructions > Page 16547
View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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Diagram Information and Instructions > Page 16553
7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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Diagram Information and Instructions > Page 16554
9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Diagram Information and Instructions > Page 16568
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagram Information and Instructions > Page 16569
View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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Diagram Information and Instructions > Page 16577
must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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Diagram Information and Instructions > Page 16578
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Diagram Information and Instructions > Page 16579
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Diagram Information and Instructions > Page 16582
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 16583
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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Diagram Information and Instructions > Page 16584
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagram Information and Instructions > Page 16585
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 16588
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 16589
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 16590
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 16591
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page
16592
Daytime Running Lamp: Service and Repair
Daytime Running Lamps (DRL) Resistor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations
Dimmer Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16596
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16597
Dimmer Switch: Diagrams
Component Connector End Views
Dimmer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 16598
Dimmer Switch: Service and Repair
Instrument Panel Lamp Dimmer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service
and Repair > Dome Lamp Bulb Replacement (Without DVD)
Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement (Without DVD)
Dome Lamp Bulb Replacement (Without DVD)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service
and Repair > Dome Lamp Bulb Replacement (Without DVD) > Page 16604
Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement (With DVD)
Dome Lamp Bulb Replacement (With DVD)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information >
Diagrams
Dome Lamp Switch: Diagrams
Component Connector End Views - Continued
Vanity Mirror Dome Lamp Switch (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information
> Service and Repair
Fog/Driving Lamp Bulb: Service and Repair
Front Fog Lamp Bulb Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component
Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component
Information > Locations
Fog/Driving Lamp Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component
Information > Locations > Page 16618
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component
Information > Locations > Page 16619
Fog/Driving Lamp Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component
Information > Locations > Page 16620
Fog/Driving Lamp Switch: Service and Repair
Fog Lamp Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations
Hazard Warning Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 16625
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 16626
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 16627
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
Headlamp Bulb Replacement (Equinox)
Removal Procedure
1. Open the hood.
2. Remove the fascia to tie bar push-in retainers (1).
3. Gently pull the top of the fascia assembly several inches away from the vehicle to release the
radiator grille strap from the headlamp. 4. Place a piece of tape over the radiator grille strap to
headlamp retaining clip to prevent scratching of the headlamp lens.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 16632
5. Remove the headlamp bolts (1, 2).
6. Pull gently on the bottom outboard corner of the headlamp to disengage the lower rear
headlamp retainer. 7. Remove the headlamp from the vehicle.
Installation Procedure
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 16633
1. Position the headlamp into the headlamp opening.
2. Push the headlamp back into position until the lower rear retainer is fully engaged.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 16634
Notice: Refer to Fastener Notice.
3. Install the headlamp bolts (1, 2)
Tighten the headlamp bolts to 2.5 N.m (22 lb in).
4. Remove the tape from the radiator grille strap retainer.
5. Position the fascia assembly and engage the radiator grille strap retainer into the headlamp.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 16635
6. Install the fascia to tie bar push-in retainers (1). 7. Close the hood. 8. Check and adjust the front
headlamp aim after the headlamp has been reinstalled. Refer to Headlamp Aiming.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical
Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention
Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage
Prevention
INFORMATION
Bulletin No.: 02-08-42-001D
Date: June 21, 2010
Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior
Polycarbonate Headlamp Lenses
Models:
2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2,
H3 2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add model years and to revise the warning statements.
Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories).
The bulletin is being issued to make dealers and customers aware of chemical damage that may
be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types
of headlamp lenses. This material is used because of its temperature and high impact resistance.
A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are
very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when
treating a vehicle with any type of chemical, such as those recommended for rail dust removal.
Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash
soaps in too high a concentration may also attribute to this condition. This could result in the need
to replace the entire headlamp housing.
Warning
Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and
lenses.
Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over
the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are
on. This action restricts the amount of heat dissipated by the headlamps.
Warning
Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is
being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause
excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens
can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it
could cause the lens to deform. This damage can also be caused by aftermarket shields that are
often tinted in color.
Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins.
This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks.
In more extreme cases, it will begin to melt the lens of the headlamp.
Notice
Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are
not covered under the new vehicle warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
Horn Switch: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Horn Switch 2 - Steering Wheel Control Switch - Right (UK3/K34) 3 - Steering Wheel Control
Switch - Left (UK3/K34)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page
16653
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair
License Plate Bulb: Service and Repair
License Lamp Bulb Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and
Repair
Map Light Bulb: Service and Repair
Reading Lamp Bulb Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information >
Service and Repair > Front Side Marker Lamp Bulb Replacement (Equinox)
Marker Lamp Bulb: Service and Repair Front Side Marker Lamp Bulb Replacement (Equinox)
Front Side Marker Lamp Bulb Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information >
Service and Repair > Front Side Marker Lamp Bulb Replacement (Equinox) > Page 16667
Marker Lamp Bulb: Service and Repair Rear Side Marker Lamp Bulb Replacement (Equinox)
Rear Side Marker Lamp Bulb Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information >
Service and Repair > Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp)
Parking Light Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Equinox Park
Lamp)
Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information >
Service and Repair > Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp) > Page 16676
Parking Light Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Equinox Turn
Lamp)
Park/Turn Signal Lamp Bulb Replacement (Equinox Turn Lamp)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Component Information > Locations
Backup Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Fog/Driving Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
High Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Locations
Low Beam Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
Ambient Light Sensor: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 16703
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 16704
Ambient Light Sensor: Diagrams
Component Connector End Views
Ambient Light Sensor
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 16705
Ambient Light Sensor: Service and Repair
Ambient Light Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Service and Repair > Brake Pedal Position Sensor Calibration
Brake Light Switch: Service and Repair Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Calibration
Calibration Criteria
The brake pedal position sensor (BPPS) receives a low reference signal and a 5-volt reference
signal from the BCM. Whenever the brake pedal is applied, the BPPS applies a variable voltage
signal to the BCM through the stop lamp switch signal circuit. The BPPS calibration must be
performed after the BPPS or body control module (BCM) have been serviced. The calibration
procedure will set BPPS home value. This value is used by the BCM to determine the action of the
driver applying the brake system and to provide this information to the vehicle subsystems via the
communication bus.
Calibration Procedure
* Install a scan tool.
* Turn ON the ignition, with the engine OFF.
* Select Diagnostics.
* Select the year.
* Select the vehicle type.
* Select BCM.
* Select Module Setup.
* Select the BPPS calibration procedure and follow the directions displayed on the screen.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Service and Repair > Brake Pedal Position Sensor Calibration > Page 16710
Brake Light Switch: Service and Repair Brake Pedal Position Sensor Replacement
Brake Pedal Position Sensor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Locations > Page 16714
Combination Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Locations > Page 16715
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch >
Component Information > Diagrams
Dome Lamp Switch: Diagrams
Component Connector End Views - Continued
Vanity Mirror Dome Lamp Switch (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations
Fog/Driving Lamp Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 16722
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 16723
Fog/Driving Lamp Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp
Switch > Component Information > Locations > Page 16724
Fog/Driving Lamp Switch: Service and Repair
Fog Lamp Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations
Hazard Warning Switch: Locations
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 16728
11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 16729
Hazard Warning Switch: Diagrams
Component Connector End Views
Hazard Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Locations > Page 16730
Hazard Warning Switch: Service and Repair
Hazard Warning Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
Horn Switch: Locations
Instrument Panel/Center Console Component Views
Steering Wheel Components
1 - Horn Switch 2 - Steering Wheel Control Switch - Right (UK3/K34) 3 - Steering Wheel Control
Switch - Left (UK3/K34)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations > Page 16734
Horn Switch: Diagrams
Component Connector End Views
Horn Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 16738
Turn Signal Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 16739
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 16742
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins >
Lighting - Exterior Lamp Condensation and Replacement
Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement
INFORMATION
Bulletin No.: 01-08-42-001H
Date: January 05, 2011
Subject: Exterior Lamp Condensation and Replacement Guidelines
Models:
2011 and Prior GM Passenger Cars and Trucks (including Saturn)
Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate
Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories).
The following information is being provided to better define the causes of condensation in exterior
lamps and includes guidelines for determining the difference between a lamp with a normal
atmospheric condition (condensation) and a lamp with a water leak.
Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit
very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens.
This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain
weather conditions.
Condensation occurs when the air inside the lamp assembly, through atmospheric changes,
reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly
condenses, creating a fine mist or white fog on the inside surface of the lamp lens.
Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable
bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it
through a vent system. The vent system operates at all times, however, it is most effective when
the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of
the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to
clear the lamp may vary from 2 to 6 hours.
Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of
models being manufactured today. These lamps require the replacement of the complete lamp
assembly if a bulb filament burns out.
Condensation 2006 TrailBlazer Shown
A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High
Humidity
- May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than
half the lens surface.
- The condition should clear of moisture when the vehicle is parked in a dry environment, or when
the vehicle is driven with the lights ON.
- A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR
performance.
If the above conditions are noted, the customer should be advised that replacement of a lamp
assembly may not correct this condition.
Water Leak New Style Pickup Shown
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Lighting - Exterior Lamp Condensation and Replacement > Page 16747
Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After
the Vehicle Has Been Exposed to Rain or a Car Washing Environment
- A condition that covers more than half the surface of the lamp lens.
- An accumulation of water in the bottom of the lamp assembly.
- A condition that WON'T clear when the vehicle is parked in a dry environment, or when the
vehicle is driven with the lights ON.
- A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different
performance.
Any of the above conditions would indicate the need to service the lens or lamp assembly.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Tail Lamp: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Information and Instructions > Page 16750
Tail Lamp: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 16751
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Information and Instructions > Page 16752
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Information and Instructions > Page 16838
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Information and Instructions > Page 16839
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16840
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16841
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16842
10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16843
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16844
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16845
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16846
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16847
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Tail Lamp: Service and Repair
Tail Lamp Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Trailer Lighting Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Locations
Combination Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Locations > Page 16856
Combination Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Locations > Page 16857
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp)
Turn Signal Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Equinox Park
Lamp)
Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp) > Page 16863
Turn Signal Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Equinox Turn
Lamp)
Park/Turn Signal Lamp Bulb Replacement (Equinox Turn Lamp)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Park/Turn Signal Lamp Bulb Replacement (Equinox Park Lamp) > Page 16864
Turn Signal Bulb: Service and Repair Rear Turn Signal Lamp Bulb Replacement (Equinox)
Rear Turn Signal Lamp Bulb Replacement (Equinox)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Locations
Turn Signal Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Locations > Page 16868
Turn Signal Switch: Diagrams
Component Connector End Views - Continued
Turn Signal/Multifunction Switch X1
Turn Signal/Multifunction Switch X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Locations > Page 16869
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Service and Repair > Multifunction Turn Signal Switch Housing Replacement
Turn Signal Switch: Service and Repair Multifunction Turn Signal Switch Housing Replacement
Multifunction Turn Signal Switch Housing Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information >
Service and Repair > Multifunction Turn Signal Switch Housing Replacement > Page 16872
Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement
Turn Signal Multifunction Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Vanity Lamp: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16877
Vanity Lamp: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Information and Instructions > Page 16878
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Information and Instructions > Page 16879
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Information and Instructions > Page 16880
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16972
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16973
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16974
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 16975
Vanity Lamp: Connector Views
Component Connector End Views - Continued
Vanity Mirror Map Lamp (UUC)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16985
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16986
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16987
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair
Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16993
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16994
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 16995
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service
Bulletins > Page 16996
Heated Glass Element: Locations
Electrical Center Identification Views
Fuse Block - Instrument Panel Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions
Heated Glass Element: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 16999
Heated Glass Element: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 17000
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 17001
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 17002
* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 17003
this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 17088
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Heated Glass Element: Connector Views
Component Connector End Views - Continued
Rear Defogger Grid X1
Rear Defogger Grid X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams >
Diagram Information and Instructions > Page 17098
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page
17099
Heated Glass Element: Testing and Inspection
Rear Window Defogger Malfunction
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See:
Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Diagnostic Fault Information
Circuit/System Description
When you depress the rear defogger button, voltage is supplied to the DEFOG relay coil and the
HVAC control module also illuminates the rear window defogger indicator. Battery positive voltage
is supplied at all times to the DEFOG relay switched input and the DEFOG relay coil is always
grounded. This allows battery positive voltage from the relay switched input through the switch
contacts and out the relay switched output to the rear window defogger. Ground for the rear
defogger grid is provided by G401.
When you start the engine and press the rear defogger switch for the first time, the defogger cycle
lasts for 15 minutes. Further operation results in 7.5 minute defogger cycles. The defogger cycle
resets to 15 minutes when you cycle the ignition to the OFF position and then to the ON position.
Circuit/System Verification
1. Ignition ON, observe the operation of the Rear Defogger Grid while pressing the Rear Defogger
Switch. The Rear Defogger Grid should
ACTIVATE and DEACTIVATE when changing between commanded states.
2. Command the rear window defogger indicator ON and OFF with the scan tool. The rear window
defogger indicator should turn ON and OFF when
changing between the commanded states.
‹› If the Defogger Indicator does not illuminate, replace the HVAC control module.
Circuit/System Testing
1. Ignition OFF, disconnect the REAR DEFOG relay. 2. Ignition OFF, test for less than 1.0 ohm of
resistance between the relay coil ground circuit terminal 25 and ground.
‹› If greater than the specified range, test for an open/high resistance.
3. Ignition ON, verify that a test lamp does not illuminate between the relay controlled output circuit
terminal 46 and ground.
‹› If the test lamp illuminates, test the control circuit for a short to voltage.
4. Verify that a test lamp illuminates between the relay switch B+ circuit terminal 43 and ground.
‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance. If the circuit tests normal and the RR
DEFOG circuit fuse is open, test the relay controlled output circuit terminal 46 for a short to ground.
5. Ignition OFF, disconnect the harness connectors C1 and C2 at the Rear Defogger Grid. 6.
Ignition OFF, test for less than 1.0 ohm of resistance between the Rear Defogger Grid ground
circuit terminal 1 and ground.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page
17100
‹› If greater than the specified range, test the ground circuit for an open/high resistance.
7. Connect the harness connectors at the Rear Defogger Grid. 8. Ignition ON, connect a 30-A
fused jumper wire between the relay switch B+ circuit terminal 43 and the relay controlled output
circuit terminal 46.
Verify the Rear Defogger Grid is activated.
‹› If the Rear Defogger Grid does not activate, test the control circuit for an open/high resistance. If
the circuit tests normal, test or replace the
Rear Defogger Grid.
9. Connect a test lamp between the relay coil control circuit terminal 39 and the relay coil ground
circuit terminal 25.
10. Command the Rear Defogger Grid ON and OFF by pressing the Rear Defogger Switch. The
test lamp should turn ON and OFF when changing
between the commanded states.
‹› If the test lamp is always ON, test the control circuit for a short to voltage. If the circuit tests
normal, replace the HVAC Control Module. ‹› If the test lamp is always OFF, test the control circuit
for a short to ground or an open/high resistance. If the circuit tests normal, replace the
HVAC Control Module.
11. If all circuits test normal, test or replace the DEFOG Relay.
Component Testing
Relay Test
1. Ignition OFF, disconnect the REAR DEFOG relay. 2. Test for 60-180 ohms of resistance
between terminals 85 and 86.
‹› If the resistance is not within the specified range, replace the relay.
3. Test for infinite resistance between the following terminals:
* 30 and 86
* 30 and 87
* 30 and 85
* 85 and 87
‹› If not the specified value, replace the relay.
4. Install a 25-amp fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire
between relay terminal 86 and ground. Test for
less than 2 ohms of resistance between terminals 30 and 87.
‹› If greater than the specified range, replace the relay.
Rear Window Defogger Grid Test
1. Ignition ON, turn on the rear window defogger. 2. Verify that a test lamp illuminates between
each rear window defogger grid line and ground. The test lamp should be off when testing at the
ground side of the grid and get brighter as the test lamp moves closer to the voltage supply side of
the grid. The test lamp should be dim when testing each grid line in the middle.
‹› If the test lamp remains bright at the middle of the grid line, test for an open between the test
point and the ground side of the grid.
‹› If the test lamp remains off at the middle of the grid line, test for an open between the test point
and the voltage supply side of the grid.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests and Procedures
* Liftgate Window Replacement
* Relay Replacement (Attached to Wire Harness) Relay Replacement (Within an Electrical Center)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Instrument Panel/Center Console Component Views
Power Window Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Instrument Panel/Center Console Component Views > Page 17106
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Instrument Panel/Center Console Component Views > Page 17107
Power Window Switch: Locations Door Component Views
Door Component Views
Left Rear Door Components
1 - Door Latch - Left Rear 2 - Window Switch - Left Rear 3 - Window Motor - Left Rear
Right Rear Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Instrument Panel/Center Console Component Views > Page 17108
1 - Window Switch - Right Rear 2 - Door Latch - Right Rear 3 - Window Motor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 17109
Power Window Switch: Diagrams
Component Connector End Views - Continued
Power Window Switch - Main X1
Power Window Switch - Main X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 17110
Window Switch - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 17111
Window Switch - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Locations > Page 17112
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement
Front Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Service and Repair > Front Side Door Window Switch Replacement > Page 17115
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
Front Side Door Window Regulator Motor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair
Rear Door Window Motor: Service and Repair
Rear Side Door Window Regulator Motor Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Instrument Panel/Center Console Component Views
Power Window Switch: Locations Instrument Panel/Center Console Component Views
Instrument Panel/Center Console Component Views
Instrument Panel and Console Components 1 of 3
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 17128
10 - Power Window Switch - Main 11 - Traction Control Switch (TCS) 12 - Dimmer Switch 13 Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 17129
Power Window Switch: Locations Door Component Views
Door Component Views
Left Rear Door Components
1 - Door Latch - Left Rear 2 - Window Switch - Left Rear 3 - Window Motor - Left Rear
Right Rear Door Components
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Instrument Panel/Center Console Component Views > Page 17130
1 - Window Switch - Right Rear 2 - Door Latch - Right Rear 3 - Window Motor - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 17131
Power Window Switch: Diagrams
Component Connector End Views - Continued
Power Window Switch - Main X1
Power Window Switch - Main X2
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 17132
Window Switch - Left Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 17133
Window Switch - Right Rear
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Locations > Page 17134
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement
Power Window Switch: Service and Repair Front Side Door Window Switch Replacement
Front Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Service and Repair > Front Side Door Window Switch Replacement > Page 17137
Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement
Rear Side Door Window Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information
Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 17147
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 17148
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster
Contact/Tab Repair Information > Page 17149
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information
Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair
Information
INFORMATION
Bulletin No.: 03-08-48-006H
Date: April 11, 2011
Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab
Models:
2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3
2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear
Window Defroster - RPO C49
Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate
Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories).
Repair Suggestions
Soldering Defroster Contact Tabs
In many cases the terminal tab will still be in the connector when you examine the vehicle. For
Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass),
always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector
(P/N 12034110). For all other vehicles, reconnect the original defroster tab.
In most applications it is preferable to create a new solder connection to reattach a separated rear
defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is
equal to, or stronger than, the original. The generic procedure below is not very time intensive, but
does include minor preparation work to create a good bonding surface. Be sure to follow each of
the steps, as combined they will produce the strongest bond possible. Please consider the
following before attempting the repair:
- Soldering introduces significant heat to the glass window of the vehicle. When performing the
re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and
have the solder in your other hand, ready to go, the moment you have enough heat to melt the
solder.
- If it is winter, bring the vehicle into the service garage and remove any snow from the back
window area. Allow time for the glass to warm to the temperature inside the building. Soldering
creates a "hot spot" in the glass. DO NOT solder on cold glass.
Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass
breakage. ALWAYS wear safety glasses when performing this repair!
- You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with
conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar,
making a strong and lasting repair.
- Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this
repair. Placing a shop towel under the soldering area is sufficient protection.
Soldering Procedure
1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a
new connector to the feed wire. The proper
connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5.
- Insert Delphi pick 12094430 to depress the locking tab on the terminal.
- Insert Delphi pick 12094429 to release the secondary lock tab.
Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with
moveable glass.
2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly
seated connector may cause excessive resistance
and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical
connector tab to the defroster tab.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17155
3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size
utility models) and the defroster buss bar with fine
grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder,
but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close
up of a properly prepared surface.
Tip You may want to mask the glass around the contact area with tape. This is easy to do and will
allow you to safely prepare the contact surface without the risk of scratching the glass or the black
painted shading.
Important Most rear glass has a black painted masking around the edge of the glass. When
cleaning up the connection surface, be very careful not to damage the surface of the black shading
or the surface of the glass.
4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to
remove any residual oil or dirt.
Important
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17156
You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with
conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is
available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for
this repair.
5. For this step, it is permitted that two technicians be used if required. Heat the new connector on
the surface of the buss bar that is to be soldered.
Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep
the solder ready and begin flowing out the solder as soon as the melting temperature has been
reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the
solder around the new contacts base. In this manner, as the melting point of the solder is reached,
a layer is deposited on the bottom side of the contact.
Important Try to align the new contact so that it is positioned with the same orientation as the
original contact.
6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the
performance of the bond; however, while it is unlikely
that customers may refer to the appearance of the rear window defroster and its components as a
positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor
cosmetic application.
*We believe this source and their products to be reliable. There may be additional manufacturers of
such products/materials. General Motors does not endorse, indicate any preference for, or assume
any responsibility for the products or material from this firm or for any such items that may be
available from other sources.
Parts Information
Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada,
1-800-563-1717).
Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at
1-800-843-7422.
All other parts can be ordered through GMSPO or SSPO.
Warranty Information (excluding Saab U.S. Models)
For vehicles repaired under warranty, use:
Warranty Information (Saab U.S. Models)
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr >
11 > A/C - Window Defroster Contact/Tab Repair Information > Page 17157
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep
> 10 > Body - Vehicle Glass Distortion Information
Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10
> Body - Vehicle Glass Distortion Information
Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass >
Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion
Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 17175
Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information
INFORMATION
Bulletin No.: 06-08-64-001B
Date: October 20, 2009
Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock
Box
Models:
2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3
2009 and Prior Saab 9-7X
Supercede: This bulletin is being revised to add vehicles and model years and to include all types of
door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body &
Accessories).
- In several warranty parts review cases, side door window glass was observed with a chip or chips
on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box
on the front side door window glass.
- A random selection of side door glass returns will be conducted to confirm adherence. If a side
door glass is discovered with a chip or chips in the location previously described, the side door
glass will be returned to the dealership for debit.
Example of Side Door Glass
- DO NOT place a vehicle key lock box on a side door window glass.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information > Page 17176
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information
Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information
INFORMATION
Bulletin No.: 00-08-48-005D
Date: September 10, 2010
Subject: Distortion in Outer Surface of Vehicle Glass
Models:
2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior
HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn
Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin
Number 00-08-48-005C (Section 08 - Body and Accessories).
Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after
the vehicle has:
- Accumulated some mileage.
- Been frequently washed in automatic car washes, particularly "touchless" car washes.
This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into
the surface of the glass.
Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the
glass. This should not cause a problem if used in the correct concentration. However, if not used
correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the
outer surface of the glass which cannot be removed by scraping or polishing.
If this condition is suspected, look at the area of the windshield under the wipers or below the belt
seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and
what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also
see a line on the glass where the wiper blade or the belt seal contacts the glass.
Important The repair will require replacing the affected glass and is not a result of a defect in
material or workmanship. Therefore, is not covered by New Vehicle Warranty.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator >
System Information > Service and Repair
Front Door Window Regulator: Service and Repair
Front Side Door Window Regulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator >
System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
Rear Side Door Window Regulator Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information >
Service and Repair
Windshield Moulding / Trim: Service and Repair
Windshield Frame Applique Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems >
Windshield Washer Relay > Component Information > Locations
Windshield Washer Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Locations > Page 17204
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Locations > Page 17205
Windshield Washer Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Locations > Page 17206
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch
Replacement
Windshield Washer Switch: Service and Repair Rear Window Wiper and Washer Switch
Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch
Replacement > Page 17209
Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch
Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch
Replacement > Page 17210
2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 17214
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 17215
Wiper Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 17216
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement
Wiper Switch: Service and Repair Rear Window Wiper and Washer Switch Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page
17219
Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page
17220
2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information >
Service and Repair > Windshield Washer Hose Replacement
Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement
Windshield Washer Hose Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information >
Service and Repair > Windshield Washer Hose Replacement > Page 17225
Windshield Washer Hose: Service and Repair Rear Washer Hose Replacement
Rear Washer Hose Replacement
Rear Washer Hose Routing
The rear washer hose is a component of the main body wire harness assembly. The rear washer
hose is a hard plastic convoluted tube that is wrapped in the electrical tape along with the main
body wiring harness. It starts underhood where it connects to the rear washer solvent container
hose, this is rubber tubing. The rear washer hose routes into the main body wire harness
underhood and passes through the front of the dash. The rear washer hose runs inside the vehicle
interior along the left side rocker and over the right side at the 2nd bar beneath the front seats. It
proceeds over the right side wheel housing and up the right side pillar where it connects to the
washer nozzle hose, at the top of the lift gate opening.
Removal Procedure
1. Locate the damaged section of the rear washer hose, this will be hard plastic convoluted tubing.
2. If the leak is located inside the main body wire harness, cut back the wire harness electrical tape
to expose the damaged section. 3. Cut out the damaged section of the rear washer hose.
Installation Procedure
1. Replace the damaged section of the rear washer hose.
* Use a 9.5 mm (3/8 in) vacuum hose to replace damaged section.
* Overlap the rear washer hose, the plastic tubing, by 10 mm (0.39 in) on each end.
* Retain each end of the vacuum hose with a 100 mm (4 in) cable tie.
2. Verify the repair by activating the washer system and checking for leaks. 3. If the leak was
located inside the main body wire harness, use electrical tape to retain the repaired section to the
wire harness.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information >
Service and Repair > Windshield Washer Hose Replacement > Page 17226
4. If the leak requires the rear washer hose to be removed in the front of dash grommet do the
following:
* Cut out the auxiliary washer hose hole from the grommet.
* Pass new section of the rear washer hose through the new grommet hose.
* Repair the hose on either side of the grommet.
* Test for any leaks.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Pump: > 08-08-43-005A > Jun > 08 >
Wipers/Washers - Low or No Washer Fluid Flow
Windshield Washer Pump: All Technical Service Bulletins Wipers/Washers - Low or No Washer
Fluid Flow
TECHNICAL
Bulletin No.: 08-08-43-005A
Date: June 19, 2008
Subject: Low, No Windshield Washer Flow (Replace Washer Pump Filter with Plain Grommet)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Built Prior to October 1, 2007
Supercede:
This bulletin is being revised to emphasize not to replace the washer pump motor and to check the
washer fuse. Please discard Corporate Bulletin Number 08-08-43-005 (Section 08 - Body and
Accessories).
Condition
Some customers may comment on low or no windshield washer flow.
Cause
This condition may be caused by a clogged washer pump filter. Extended use with the filter
clogged may have also caused the washer pump to burn out.
Correction
Technicians are to replace the pump filter with a new style plain grommet.
Important:
If further diagnosis leads to the washer pump motor being inoperative, replace the windshield
washer pump motor.
1. Remove the windshield washer container. Refer to SI for Windshield Washer Solvent Container
Replacement.
2. Remove the washer solvent filter grommet from the pump.
3. Replace the washer solvent pump filter grommet with a new part (see figure above).
4. Verify the washer fuse is not blown- refer to SI for the location of the fuse.
Important:
DO NOT replace the washer pump motor and kit unless further diagnosis leads you to an
inoperative pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Pump: > 08-08-43-005A > Jun > 08 >
Wipers/Washers - Low or No Washer Fluid Flow > Page 17235
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Technical Service Bulletins > Customer Interest for Windshield Washer Pump: > 08-08-43-005A > Jun > 08 >
Wipers/Washers - Low or No Washer Fluid Flow
Windshield Washer Pump: Customer Interest Wipers/Washers - Low or No Washer Fluid Flow
TECHNICAL
Bulletin No.: 08-08-43-005A
Date: June 19, 2008
Subject: Low, No Windshield Washer Flow (Replace Washer Pump Filter with Plain Grommet)
Models: 2007-2008 Chevrolet Equinox 2007-2008 Pontiac Torrent
Built Prior to October 1, 2007
Supercede:
This bulletin is being revised to emphasize not to replace the washer pump motor and to check the
washer fuse. Please discard Corporate Bulletin Number 08-08-43-005 (Section 08 - Body and
Accessories).
Condition
Some customers may comment on low or no windshield washer flow.
Cause
This condition may be caused by a clogged washer pump filter. Extended use with the filter
clogged may have also caused the washer pump to burn out.
Correction
Technicians are to replace the pump filter with a new style plain grommet.
Important:
If further diagnosis leads to the washer pump motor being inoperative, replace the windshield
washer pump motor.
1. Remove the windshield washer container. Refer to SI for Windshield Washer Solvent Container
Replacement.
2. Remove the washer solvent filter grommet from the pump.
3. Replace the washer solvent pump filter grommet with a new part (see figure above).
4. Verify the washer fuse is not blown- refer to SI for the location of the fuse.
Important:
DO NOT replace the washer pump motor and kit unless further diagnosis leads you to an
inoperative pump.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Technical Service Bulletins > Customer Interest for Windshield Washer Pump: > 08-08-43-005A > Jun > 08 >
Wipers/Washers - Low or No Washer Fluid Flow > Page 17241
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Technical Service Bulletins > Page 17242
Windshield Washer Pump: Diagrams
Component Connector End Views - Continued
Windshield Washer Fluid Pump
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Service and Repair > Washer Pump Filter Grommet Replacement
Windshield Washer Pump: Service and Repair Washer Pump Filter Grommet Replacement
Washer Pump Filter Grommet Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Service and Repair > Washer Pump Filter Grommet Replacement > Page 17245
Windshield Washer Pump: Service and Repair Washer Pump Replacement
Washer Pump Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information >
Locations
Windshield Washer Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair
Windshield Washer Reservoir: Service and Repair
Windshield Washer Solvent Container Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 17252
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair > Windshield Washer Nozzle Replacement
Windshield Washer Spray Nozzle: Service and Repair Windshield Washer Nozzle Replacement
Windshield Washer Nozzle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair > Windshield Washer Nozzle Replacement > Page 17257
Windshield Washer Spray Nozzle: Service and Repair Rear Window Washer Nozzle Replacement
Rear Window Washer Nozzle Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information
> Service and Repair > Windshield Washer Nozzle Replacement > Page 17258
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Locations
Windshield Washer Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
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Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Locations > Page 17262
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Locations > Page 17263
Windshield Washer Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
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Locations > Page 17264
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Service and Repair > Rear Window Wiper and Washer Switch Replacement
Windshield Washer Switch: Service and Repair Rear Window Wiper and Washer Switch
Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page 17267
Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch
Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.
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Service and Repair > Rear Window Wiper and Washer Switch Replacement > Page 17268
2. Connect the wipers/washer switch harness connector. 3. Install the steering column trim covers.
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Rear Window Wiper Arm Replacement
Wiper Arm: Service and Repair Rear Window Wiper Arm Replacement
Rear Window Wiper Arm Replacement
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Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Rear Window Wiper Arm Replacement > Page 17273
Wiper Arm: Service and Repair Windshield Wiper Arm Replacement
Windshield Wiper Arm Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Glass/Body - Windshield Wiper Performance
Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance
INFORMATION
Bulletin No.: 06-08-43-003C
Date: February 21, 2011
Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance
Models:
2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2,
H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X
Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard
Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories).
Wiper Concerns
Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged
wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending
on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are
some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to
avoid unnecessary replacements.
Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong
with the returned blades other than a build-up of dirt. Additionally, advise the customer to review
the information in their Owner Manual.
Inspection and Cleaning
Scheduled Maintenance
- Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or
contamination.
- Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are
not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber
elements.
Cleaning Procedure
Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct
contact with washer fluid.
Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades.
- Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid
or a mild detergent. You should see significant amounts of dirt being removed on the cloth.
- Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and
a buildup of car wash/wax treatments may additionally cause wiper streaking.
Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami*
(www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid
scratching the glass. Flush the surface and body panels completely.
Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest
Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use
foaming cleaner that quickly removes dirt and grime from glass surfaces.
Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the
window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin
Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also
recommends using plain water to clean interior glass.
*"We believe this material to be reliable. There may be additional manufacturers of such material.
General Motors does not endorse, indicate any preference for or assume any responsibility for the
products or equipment from these firms or any such items which may be available from other
sources.
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Bulletins > Glass/Body - Windshield Wiper Performance > Page 17278
Avoiding Wiper Damage
The following are major contributors to wiper damage. Some of these you can control and others
are environmental concerns.
- Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear
quickly and unevenly.
- Sand and salt used on roads for increasing winter traction and ice control will cause the wiper
blades to wear quicker. Areas with significant snowfall require more frequent blade replacements.
- Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not
flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas.
- Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a
frozen windshield can tear the rubber. Exercise caution when clearing ice and snow.
- Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the
ice, can dull, nick or tear the rubber blades.
- Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the
rubber and causing potential scratching of the windshield.
- Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To
remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the
frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition.
Note
GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid
additives. The variation in friction that results on the glass from the use of these products causes
wipers to chatter and have premature wear.
Disclaimer
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
> Procedures
Wiper Blade: Procedures
Blade Element Cleaning
Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full
strength washer solvent. Hold the blade in one hand and wipe the element with the saturated cloth
until the black residue disappears. Then rinse the blade assembly elements with clean drinkable
water.
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> Procedures > Page 17281
Wiper Blade: Removal and Replacement
Windshield Wiper Blade Replacement
Windshield Wiper Blade Replacement
Wiper Blade Element Replacement
Wiper Blade Element Replacement
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> Procedures > Page 17282
Rear Window Wiper Blade Replacement
Rear Window Wiper Blade Replacement
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> Procedures > Page 17283
Rear Window Wiper Blade Element Replacement
Rear Window Wiper Blade Element Replacement
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> Procedures > Page 17284
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and
Repair
Wiper Gear Box: Service and Repair
Air Inlet Grille Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams >
Diagram Information and Instructions
Wiper Motor: Diagram Information and Instructions
General Electrical Diagnosis
General Electrical Diagnosis
Basic Knowledge Required
Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures
contained in the Service Data. You should understand the basic theory of electricity, and know the
meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read
and understand a wiring diagram, as well as understand what happens in a circuit with an open or
a shorted wire.
Utility/Van Zoning
Utility/Van Zoning
All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that
correspond to where they are located in the vehicle. The following table explains the numbering
system.
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Diagram Information and Instructions > Page 17292
Wiper Motor: Diagnostic Aids
Arrows and Symbols
Arrows and Symbols
This service manual uses various symbols in order to describe different service operations.
Arrows and Symbols
1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or
Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or
Jelly 13 - Multidirectional Arrow
Decimal and Metric Equivalents
Decimal and Metric Equivalents
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Diagram Information and Instructions > Page 17294
Checking Aftermarket Accessories
Checking Aftermarket Accessories
Do not connect aftermarket accessories into the following circuits:
Caution: Refer to Restraint System Service Precautions.
* SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
Notice: Refer to OBD II Symbol Description Notice.
* OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.
Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the system to verify that these add-on
accessories are not the cause of the problems.
Possible causes of vehicle problems related to aftermarket accessories include:
* Power feeds connected to points other than the battery
* Antenna location
* Transceiver wiring located too close to vehicle electronic modules or wiring
* Poor shielding or poor connectors on antenna feed line
* Check for recent service bulletins detailing installation guidelines for aftermarket accessories.
Circuit Testing
Circuit Testing
The Circuit Testing section contains the following diagnostic testing information. Using this
information along with the diagnostic procedures will identify the cause of the electrical malfunction.
* Using Connector Test Adapters
* Probing Electrical Connectors
* Troubleshooting with a Digital Multimeter
* Troubleshooting with a Test Lamp
* Using Fused Jumper Wires
* Measuring Voltage
* Measuring Voltage Drop
* Measuring Frequency
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* Testing for Continuity
* Testing for Short to Ground
* Testing for a Short to Voltage
* Testing for Intermittent Conditions and Poor Connections
* Inducing Intermittent Fault Conditions
* Testing for Electrical Intermittents
* Scan Tool Snapshot Procedure
* Circuit Protection - Fuses
* Circuit Protection - Circuit Breakers
* Circuit Protection - Fusible Links
Inducing Intermittent Fault Conditions
Inducing Intermittent Fault Conditions
Tools Required
J 25070 Heat Gun
Many intermittent open or shorted circuits are affected by harness/connector movement that is
caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the
customer's concern, it may be necessary to manipulate the wiring harness if the malfunction
appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions,
including:
* Wiggling the harness
* Disconnecting a connector and reconnecting
* Stressing the mechanical connection of a connector
* Pulling on the harness or wire in order to identify a separation/break inside the insulation
* Relocating a harness or wires
All these actions should be performed with some goal in mind. For instance, with a scan tool
connected, wiggling the wires may uncover a faulty input to the control module. The snapshot
option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with
the component commanded ON and OFF by the scan tool, move related connectors and wiring
and observe the component operation. With the engine running, move related connectors and
wiring while monitoring engine operation. If harness or connector movement affects the data
displayed, component/system operation, or engine operation, inspect and repair the
harness/connections as necessary. See: Testing and Inspection/Component Tests and General
Diagnostics
You may need to load the vehicle in order to duplicate the concern. This may require the use of
weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to
duplicate the concern by manipulating the suspension or frame. This method is useful in finding
harnesses that are too short and their connectors pull apart enough to cause a poor connection. A
DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield
desirable results. Refer to Testing for Electrical Intermittents. See: Testing and
Inspection/Component Tests and General Diagnostics
Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide
good results as well.
There may be instances where circuit manipulation alone will not meet the required criteria for the
fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other
conditions while manipulating the harness. Such conditions would include high moisture conditions,
along with exceptionally high or low temperatures. The following discusses how to expose the
circuit to these kinds of conditions.
Salt Water Spray
Some compounds possess the ability to conduct electricity when dissolved in water such as
ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the
conductive properties of water so that any circuit which may be sensitive to moisture will more
readily fail when liberally sprayed with this mixture.
Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5
percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's
own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is
completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan
tool or DMM, manipulate the harness as discussed previously.
High Temperature Conditions
If the complaint tends to be heat related, you can simulate the condition using the J 25070.
Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses
under high temperature conditions while monitoring the scan tool or DMM to locate the fault
condition.
The high temperature condition may be achieved simply by test driving the vehicle at normal
operating temperature. If a heat gun is unavailable, consider
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this option to enhance your diagnosis. This option does not allow for the same control, however.
Low Temperature Conditions
Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle
is in the shade can have the desired effect.
If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that
provides hot or cold air). This type of tool is capable of producing air stream temperatures down to
-18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized
cooling needs.
Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or
components in an effort to duplicate the concern.
Duplicating Failure Conditions
* If none of the previous tests are successful, attempt to duplicate and/or capture the failure
conditions.
* Freeze Frame/Failure Records data, where applicable, contains the conditions that were present
when the DTC set.
1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that
were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must
also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the
DTC in the supporting text if a DTC is being diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling
conditions have been satisfied long enough
for the DTC to run. The scan tool will also indicate whether the DTC passed or failed.
* An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An
abnormal reading on the DMM when the concern occurs, may help you locate the concern.
Measuring Frequency
Measuring Frequency
Notice: Refer to Test Probe Notice.
The following procedure determines the frequency of a signal.
Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to
autorange to an appropriate range.
1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect
the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to
a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency
measured.
Measuring Voltage
Measuring Voltage
Notice: Refer to Test Probe Notice.
The following procedure tests for a short to voltage in a circuit.
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4.
Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt,
there is a short to voltage in the circuit.
Measuring Voltage Drop
Measuring Voltage Drop
Notice: Refer to Test Probe Notice.
The following procedure determines the difference in voltage potential between 2 points.
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Diagram Information and Instructions > Page 17297
1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to
one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of
the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2
points.
Probing Electrical Connectors
Probing Electrical Connectors
Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position
assurance (TPA) when reconnecting connectors or replacing terminals.
Frontprobe
Disconnect the connector and probe the terminals from the mating side (front) of the connector.
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Important: When probing female 0.64 terminals, it is important to use the correct adapter. There
have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64
terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip.
Failure to use the proper test adapter may result in damage to the terminal being tested and
improper diagnosis.
Refer to the following table as a guide in selecting the correct test adapter for frontprobing
connectors:
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Diagram Information and Instructions > Page 17298
Backprobe
Important:
* Backprobe connector terminals only when specifically required in diagnostic procedures.
*
Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack
connector, a Micro-Pack connector, or a flat wire (dock and lock) connector.
* Backprobing can be a source of damage to connector terminals. Use care in order to avoid
deforming the terminal, either by forcing the test probe too far into the cavity or by using too large
of a test probe.
* After backprobing any connector, inspect for terminal damage. If terminal damage is suspected,
test for proper terminal contact.
Do not disconnect the connector and probe the terminals from the harness side (back) of the
connector.
Scan Tool Snapshot Procedure
Scan Tool Snapshot Procedure
Snapshot is a recording of what a control module on the vehicle was receiving for information while
the snapshot is being made. A snapshot may be used
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to analyze the data during the time a vehicle condition is current. This allows you to concentrate on
making the condition occur, rather than trying to view all the data in anticipation of the fault. The
snapshot contains information around a trigger point that you have determined. Only a single data
list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The
ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle
scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the
first snapshot stored in the memory will be lost.
Snapshots can be 1 of 2 types:
* Snapshot - taken from the Snapshot menu choice
* Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information
When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200
frames of information. Because the snapshot is recorded onto the memory card, snapshots are not
lost if the Scan Tool is powered down.
The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis.
The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected
values by plotting 3 parameters at a time. The data will be displayed both graphically and
numerically showing the minimum and maximum values for all frames captured. This is helpful,
especially if the fault occurs only once and does not set a DTC.
Testing for a Short to Voltage
Testing for a Short to Voltage
Notice: Refer to Test Probe Notice.
The following procedure measures the voltage at a selected point in a circuit.
1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable
the circuit and/or system being tested. Use the following methods:
* Turn ON the ignition, with the engine OFF.
* Turn ON the engine.
* Turn ON the circuit and/or system with a scan tool in Output Controls.
* Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the
point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The
DMM displays the voltage measured at that point.
Testing for Continuity
Testing for Continuity
Notice: Refer to Test Probe Notice.
The following procedures verify good continuity in a circuit.
With a DMM
1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse,
control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on
the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the
other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance,
the circuit has good continuity.
With a Test Lamp
Important: Only use the test lamp procedure on low impedance power and ground circuits.
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the
other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to
ground.
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6. If the test lamp illuminates (full intensity), then the circuit has good continuity.
Testing for Electrical Intermittents
Testing for Electrical Intermittents
Tools Required
J 39200 Digital Multimeter
Perform the following procedures while wiggling the harness from side to side. Continue this at
convenient points (about 6 inches apart) while watching the test equipment.
* Testing for Short to Ground
* Testing for Continuity
* Testing for a Short to Voltage
If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200
DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J
39200 will generate an audible tone when a change is detected.
Important: The J 39200 must be used in order to perform the following procedure since the J 39200
can monitor current, resistance or voltage while recording the minimum (MIN), and maximum
(MAX) values measured.
1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of
a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC)
position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4.
Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an
audible tone (beep).
Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in
order to record the full change.
5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling
the connections or the wiring, test driving, or
performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has
been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the
value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9.
Determine the difference between the MIN and MAX values.
* If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an
intermittent open or high resistance condition exists. Repair the condition as necessary.
* If the variation between the recorded MIN and MAX voltage values is less than 1 volt an
intermittent open or high resistance condition does not exist.
Testing for Intermittent Conditions and Poor Connections
Testing for Intermittent Conditions and Poor Connections
Tools Required
* J 35616 GM-Approved Terminal Test Kit
* J-38125 Terminal Repair Kit
When the condition is not currently present, but is indicated in DTC history, the cause may be
intermittent. An intermittent may also be the cause when there is a customer complaint, but the
symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of
causing the condition before trying to locate an intermittent condition.
Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the
following items:
* Wiring broken inside the insulation
* Poor connection between the male and female terminal at a connector
* Poor terminal to wire connection-Some conditions which fall under this description are poor
crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion
in the wire to terminal contact area, etc.
* Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The
conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff
sections of wire in the suspect circuits.
* Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent
open or short as the bare area touches other wiring or parts of the vehicle.
* Wiring that comes in contact with hot or exhaust components
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* Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in
order to verify the customer concern. See: Testing and Inspection/Component Tests and General
Diagnostics
* Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high
resistance, short to ground, and short to voltage conditions. See: Testing and
Inspection/Component Tests and General Diagnostics
* Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data
Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics
Testing for Proper Terminal Contact
It is important to test terminal contact at the component and any inline connectors before replacing
a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor
connection between the male and female terminal at a connector may be the result of
contamination or deformation.
Contamination may be caused by the connector halves being improperly connected. A missing or
damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and
dirt can also cause contamination. Contamination, usually in the underhood or underbody
connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.
Deformation is caused by probing the mating side of a connector terminal without the proper
adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation
are improperly joining the connector halves, or repeatedly separating and joining the connector
halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact
causing an open or intermittently open circuit.
Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC)
It is very important to use the correct test adapter when testing for proper terminal contact of fuses
and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact.
Failure to use J-35616-35 can result in improper diagnosis of the BEC.
Follow the procedure below in order to test terminal contact:
1. Separate the connector halves. 2. Visually inspect the connector halves for contamination.
Contamination may result in a white or green build-up within the connector body or
between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An
underhood or underbody connector that shows signs of contamination should be replaced in its
entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly
different between a good terminal and a suspect
terminal. Replace the female terminal in question.
Flat Wire (Dock and Lock) Connectors
There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the
component side.
Follow the procedure below in order to test terminal contact:
1. Remove the component in question. 2. Visually inspect each side of the connector for signs of
contamination. Avoid touching either side of the connector as oil from your skin may be a
source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other
imperfections that could cause poor terminal
contact. Visually inspect the component side connector to ensure that all of the terminals are
uniform and free of damage or deformation.
4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the
circuit in question.
Control Module/Component Voltage and Grounds
Poor voltage or ground connections can cause widely varying symptoms.
* Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying
voltage to a control module. Other components in the system may have separate voltage supply
circuits that may also need to be tested. Inspect connections at the module/component connectors,
fuses, and any intermediate connections between the voltage source and the module/component.
A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit
to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the
component. Refer to Circuit Testing and Power Distribution Schematics. See: Testing and
Inspection/Component Tests and General Diagnostics
* Test all control module ground and system ground circuits. The control module may have multiple
ground circuits. Other components in the system may have separate grounds that may also need
to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the
connections at the component and in splice packs, where applicable. Ensure that the circuit can
carry the current necessary to operate the component. Refer to Circuit Testing and Ground
Distribution Schematics. See: Testing and Inspection/Component Tests and General Diagnostics
Temperature Sensitivity
* An intermittent condition may occur when a component/connection reaches normal operating
temperature. The condition may occur only when the component/connection is cold, or only when
the component/connection is hot.
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* Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type
of intermittent condition, where applicable.
* If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures
- Underhood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
* If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a connection or
component. Inspect for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
* Information from the customer may help to determine if the trouble follows a pattern that is
temperature related.
* If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the
condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions
required. See: Testing and Inspection/Component Tests and General Diagnostics
Electromagnetic Interference (EMI) and Electrical Noise
Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other
types of electrical noise. Inspect for the following conditions:
* A misrouted harness that is too close to high voltage/high current devices such as secondary
ignition components, motors, generator etc-These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
* Electrical system interference caused by a malfunctioning relay, or a control module driven
solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will
occur when the malfunctioning component is operating.
* Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way
radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These
accessories may lead to interference while in use, but do not fail when the accessories are not in
use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests
and General Diagnostics
* Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays
may contain a clamping diode.
* The generator may be allowing AC noise into the electrical system.
Incorrect Control Module
* There are only a few situations where reprogramming a control module is appropriate:
- A new service control module is installed.
- A control module from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
Important: DO NOT re-program the control module with the SAME software/calibration files that are
already present in the control module. This is not an effective repair for any type of concern.
* Verify that the control module contains the correct software/calibration. If incorrect programming
is found, reprogram the control module with the most current software/calibration.
Testing for Short to Ground
Testing for Short to Ground
Notice: Refer to Test Probe Notice.
The following procedures test for a short to ground in a circuit.
With a DMM
1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one
end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the
DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.
With a Test Lamp
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1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the
load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of
the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to
ground in the circuit.
Fuse Powering Several Loads
1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or
switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure
that the fuse is powered).
* When the DMM displays voltage the short is in the wiring leading to the first connector or switch.
* If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is
shorted.
Troubleshooting with a Digital Multimeter
Troubleshooting with a Digital Multimeter
Notice: Refer to Test Probe Notice.
Important: Circuits which include any solid state control modules, such as the powertrain control
module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter
such as the J 39200 Digital Multimeter (DMM).
The J 39200 instruction manual is a good source of information and should be read thoroughly
upon receipt of the DMM as well as kept on hand for future reference.
A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits.
While a test lamp shows whether voltage is present if the impedance is low enough, a DMM
indicates how much voltage is present. In other words, if there is not enough current, the test lamp
will not illuminate even though voltage is present.
The ohmmeter function on a DMM shows how much resistance exists between 2 points along a
circuit. Low resistance in a circuit means good continuity.
Important: Disconnect the power feed from the suspect circuit when measuring resistance with a
DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance
that the presence of voltages can upset a resistance reading.
Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find
out if a component is affecting a measurement take a reading once, then reverse the leads and
take a second reading. If the readings differ the solid state component is affecting the
measurement.
Following are examples of the various methods of connecting the DMM to the circuit to be tested:
* Backprobe both ends of the connector and either hold the leads in place while manipulating the
connector or tape the leads to the harness for continuous monitoring while you perform other
operations or test driving. Refer to Probing Electrical Connectors. See: Testing and
Inspection/Component Tests and General Diagnostics
* Disconnect the harness at both ends of the suspected circuit where it connects either to a
component or to other harnesses.
* If the system that is being diagnosed has a specified pinout or breakout box, it may be used in
order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly.
Troubleshooting With A Test Lamp
Troubleshooting with a Test Lamp
Tools Required
J 35616-200 Test Light - Probe Kit
Notice: Refer to Test Probe Notice.
A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used
instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp
shows whether voltage is present if the impedance is low enough, a DMM indicates how much
voltage is present. In other words, if there is not enough current, the test lamp will not illuminage
even though voltage is present.
The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached
pair of leads.
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To properly operate this tool use the following procedures.
When testing for voltage:
1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where
voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested.
When testing for ground:
1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the
circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point
being tested.
Using Connector Test Adapters
Using Connector Test Adapters
Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal.
The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor
connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal
Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe
terminals.
When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice
is the correct size for the connector terminal. Do not visually choose the terminal test adapter
because some connector terminal cavities may appear larger than the actual terminal in the cavity.
Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved
Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct
adapter along with the connector end view for terminal size.
Using Fused Jumper Wires
Using Fused Jumper Wires
Tools Required
J 36169-A Fused Jumper Wire
Important: A fused jumper may not protect solid state components from being damaged.
The J 36169-A includes small clamp connectors that provide adaptation to most connectors without
damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some
circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.
AFL/ECP Connectors
AFL/EPC Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the
connector from the component.
2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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3. Slide the lever lock forward while pressing down on the lever lock release tab.
View showing depressing of the lever lock release tab.
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View of connector in released position.
4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
6. Release the rear lower half of the wiredress cover.
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7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the
nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body.
Gently pry the nose piece out of the
connector. J 38125-216 can also be used to remove the nose piece.
9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal
retaining tabs on the inside of the connector. See the
release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
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10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (BSK)
Bosch Connectors (BSK)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
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4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the
connector and push until you feel the tool disengage
the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Bosch Connectors (ECM)
Bosch Connectors (ECM)
Tools Required
J-38125Terminal Repair Kit
Removal Procedure
1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position.
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2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to
release the locking tabs and remove the dress
cover.
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4. The terminal positive assurance (TPA) is located in the front of the connector.
5. Use a small flat-blade tool to remove TPA from the connector.
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6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Important: Ensure that the dress cover and connector body are both in the released position before
reassembling. Failure to do so may cause damage to the connector and component.
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Bosch Connectors (0.64)
Bosch Connectors (0.64)
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Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and
past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the
component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector
dress cover. 4. Place the connector locking lever in the center of the connector.
5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small
flat-bladed tool between the cover and connector
body and pry up.
6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a
small flat-bladed tool between the cover at the
connector end and pry up.
7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle.
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9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small
slot in the end of the slider and pushing on the
TPA until it comes out of the connector. When the TPA exits the opposite side of the connector,
gasp the TPA and pull it completely out of the connector.
10. Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the
terminal at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
12. Carefully pull the terminal out of the connector. Always remember never use force when pulling
a terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Terminal Replacement Procedure
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1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding
grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the
retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and
seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4.
Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet.
Bosch Connectors (2.8 JPT)
Bosch Connectors (2.8 JPT)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2.
Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4.
Push the wire side of the terminal that is being removed toward the connector and hold it in
position.
5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the
front of the connector and push until you feel the
tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a
terminal out of a connector. If the terminal is
difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
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Connector Position Assurance Locks
Connector Position Assurance Locks
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in
all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the mating
terminals, of the connector.
Connector Repairs
Connector Repairs
Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the
connector manufacturer and then by connector type. If the technician cannot identify the
manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector
manufacturer will assist in finding the correct connector repair from the following list:
* Connector Position Assurance Locks
* Terminal Position Assurance Locks
* Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch
Connectors (ECM)
* Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To
Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors
(12-Way)
* Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors
(0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module)
* Yazaki Connectors (2-Way) Yazaki Connectors (16-Way)
* Repairing Connector Terminals
Connector Anatomy
1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief
5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal
Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector
Identifying Connectors
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Knowing the connector manufacturer is helpful when trying to locating the correct connector repair
procedure. There are many different connector designs used on GM vehicles and it is sometimes
difficult to identify the connector manufacturer. The information in this document should help with
the identification of connector manufactures.
The following connector manufacturers make most of the connectors found in GM vehicles:
* AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components)
* Bosch
* Delphi
* FCI (Framatome Connectors International)
* JAE (Japan Aviation Electronics)
* JST (Japan Solderless Terminals)
* Kostel
* Molex
* Sumitomo
* Tyco/AMP
* Yazaki
Identifying the manufacturer of a connector is often difficult. When trying to determine the
manufacturer of a connector, look for specific identifying marks that are unique to that connector
supplier. Most of these identify marks are hard to find or see. Check the connector carefully and
refer to the information below for pictures and descriptions of connector identification markings.
* Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will
not have any markings on them.
* In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the
connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo
can appear anywhere on the connector and is often very small.
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* In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the
connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they
can appear anywhere on the connector.
* FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A"
above it.
* JAE connector have JAE in small letters on their connectors.
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* JST connectors have JST in small letters on their connectors, similar to that above. The location
of the logo will vary with the connector size and style.
* Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions
connection.
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* Most Molex connectors will have the Molex logo on the dresscover of the connector. In some
cases the connectors may have MX followed by another letter. The third letter indicates where the
connector was made. A connector with MXD is a Molex connector made in Detroit.
Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is
similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere
but the most common place is at the wire side of the housing.
* Tyco/AMP has many different and unique connector designs. Some may or may not have
identifiable marks on them.
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* Yazaki has a wedge or arrow shape, similar to that shown.
Delphi Connectors (Micro .64)
Delphi Connectors (Micro.64)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from Micro.64 connectors.
1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and
past the lock. The lever lock may be located on
the top or sides of the wire dress cover.
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View of a typical Micro 64 connector.
Depress the lock and pull the lever over and past the lock.
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View of the connector when released from the component.
View of another type of Micro 64 connector.
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Depress the locks that are located on both sides of the wiredress cover and pull the lever over and
past the locks.
View of the connector when released from the component.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool
push down on one of the locking tabs and pull the
cover up until the dress cover releases. Repeat this procedure for the other locking tab.
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4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward.
Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing
down until the TPA releases. Gently pry the TPA
out of the connector.
Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or
the tool may break.
6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals
cavities at the front of the connector. See the release
tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Follow the steps below in order to repair Micro 64 connector terminals.
The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping.
In order to aid the technician when crimping these terminals, a new crimping tool was developed.
The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool
has a terminal holding block that will hold the terminal in place while the terminal is being crimped.
The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same
time.
After the terminal is removed from the connector perform the following procedure in order to repair
Micro 64 terminals.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation
from the wire.
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3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely
visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct
terminal holder is determined by the wire size. Also
ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the
terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7.
Place the terminal into the appropriate cavity and assemble the connector.
Delphi Connectors (Micro-Pack 100W)
Delphi Connectors (Micro-Pack 100W)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use
different terminals and have some minor physical differences also.
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The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds
the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the
terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and
offset from the other row of terminal cavities in the connector. The second design has terminals
cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to
identify the second design is the thin strip of material that runs along the outside of the cavities.
Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you
have the correct terminal before crimping the new terminal to the wire. The first design connector
uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second
design connector uses the shorter terminal without the raised area.
Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some
Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.
1. Disconnect the connector from the component.
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2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.
The connector nose piece acts as a terminal positive
assurance (TPA) and may be referred to as such.
3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same
side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose
piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover
removal. Use this procedure as a guide, some dress cover
removal procedures may vary.
6. Use fingers to squeeze the 2 locking legs of the cover.
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7. Apply pressure and gently rock the cover until one locking leg is unseated.
8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat
procedure for the other side of the dress cover and
remove the cover.
9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling
the wire out of the back of the connector.
Always remember never use force when pulling a terminal out of a connector. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the
wire out of the front of the connector instead of
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pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal
is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire
through the connector.
Terminal Repair Procedure
The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when
crimping. In order to aid the technician when crimping these terminals, a new crimping tool was
developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W
terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the
terminal in place while the terminal is being crimped. After the terminal is removed from the
connector perform the following procedure in order to repair Micro-Pack 100 terminals.
1. Cut the wire as close to the terminal as possible.
Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long
enough to reach the connector without putting a strain on the wire. If the wire is not long enough,
splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the
added wire.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal
holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp
tool. Be sure that the wings are pointed toward the
crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect
the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than
the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the
emergency release to open applicator.
Terminal Replacement Procedure
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After the terminal is crimped to the wire perform the following procedure in order to replace
Micro-Pack 100 terminals.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the Terminal Removal Procedure.
Delphi Connectors (Pull To Seat)
Delphi Connectors (Pull To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should
be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2.
Disconnect the connector from the component or separate the connectors for in-line connectors. 3.
Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into
the front of the connector body.
Important: On connectors with more than one terminal the service loop may not be large enough to
remove the terminal and crimp on a new one. If the terminal wire does not have a large enough
service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal.
5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the
connector body.
Terminal Repair
1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the
same size wire through the back of the connector
cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not
cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the
crimp with rosin core solder.
Terminal Installation
1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.
2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing
Copper Wire Using Splice Sleeves. See: Testing
and Inspection/Component Tests and General Diagnostics
3. If the connector is outside of the passenger compartment, apply dielectric grease to the
connector.
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4. Install the TPA, CPA, and/or the secondary locks.
Delphi Connectors (Push To Seat)
Delphi Connectors (Push To Seat)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA)
device, and/or the secondary lock. 2. Separate the connector halves (1).
3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool
cross reference in the Reference Guide of the J-38125
to ensure that the correct release tool is used.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal,
refer to Terminal Repair.
Terminal Repair
1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3.
Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a
new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward
the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the
passenger compartment, apply grease to the connector.
Reinstalling Terminal
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1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and
Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the
terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA,
and/or the secondary locks.
Delphi Connectors (Weather Pack)
Delphi Connectors (Weather Pack)
Tools Required
J-38125 Terminal Repair Kit
The following is the proper procedure for the repair of Weather Pack(R) Connectors.
1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in
terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the
terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the
front (mating end) of the connector cavity until it
rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).
Important: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2)
and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify
that circuit is complete and working satisfactorily.
10. Perform system check.
Delphi Connectors (12 Way)
Delphi Connectors (12-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
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1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA)
and slide the lever lock away from the connector
body.
2. Disconnect the connector from the component.
3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade
tool release all of the locking tabs.
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4. Release the lower wiredress cover locking tab.
5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress
cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the
TPA. Gently pry the TPA out of the connector.
8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of
the nose piece. Gently pry the nose piece out of
the connector.
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9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into
the terminal release cavity. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
10. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
FCI Connectors
FCI Connectors
Tools Required
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J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Slide the lever lock forward while pressing down on the lever lock release tab.
The release tab is located on the top of the wiredress cover.
View of connector in released position.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the
corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the
dress
cover.
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4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both
ends of the connector. The TPA is located
underneath the wire dress cover.
For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by
inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560
(GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that
the correct release tool is used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
JST Connectors
JST Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, remove the connector from the component.
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2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the
connector body.
3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector.
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Important: The TPA cannot be removed from the connector while there are terminals present in the
connector body.
View of the TPA when removed from the connector body.
4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the
terminal release cavity as shown in the graphic. Use
the tool to move the terminal release to the right with a gentle prying motion. See the release tool
cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is
used.
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5. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Kostal Connectors
Kostal Connectors
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
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View of typical connector.
View of connector in released position.
1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2.
Disconnect the connector from the component.
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3. Use a small flat-blade tool to remove the dress cover.
4. Slide the dress cover forward and off of the connector.
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5. The terminal positive assurance (TPA) is located in the front and rear of the connector.
6. Use a small flat-blade tool to remove the rear TPA from the connector.
Important: The front TPA cannot be removed from the connector. Only move it to the release point.
7. Use a small flat-blade tool to move the front TPA to the release position.
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8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by
inserting the tool into the terminal release cavity. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
9. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Molex Connectors
Molex Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA
forward.
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2. Slide the lever lock forward while pressing down on the lever lock release tab.
3. The lever should be in the full forward position.
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4. Disconnect the connector from the component.
5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and
lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body.
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7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When
the nose piece is in the pre-staged position, the nose
piece will be raised above the connector body the length of the step in the nose piece.
8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose
piece is higher than the first step in the nose piece,
gently push down on the nose piece until it meets with resistance from the connector body, you
should feel the nose piece click into position.
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9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on
the back of the wire.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Insure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Repairing Connector Terminals
Repairing Connector Terminals
Tools Required
J-38125 Terminal Repair Kit
Use the following repair procedures in order to repair the following:
* Push to Seat terminals
* Pull to Seat terminals
Some terminals do not require all of the steps shown. Skip the steps that do not apply for your
terminal repair. The J-38125 contains further information.
1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used.
Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable
insulation. 5. Position the strip in the terminal.
For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings. 7. Hand crimp the insulation wings.
For sealed terminals, hand crimp the insulation wings around the seal and the cable.
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8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack
100 World terminals may damage the terminal.
Sumitomo Connectors
Sumitomo Connectors
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Slide the lever lock forward while pressing down on the lever lock release tab.
2. Disconnect the connector from the component.
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3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and
pulling off the dress cover.
4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the
single retainer slot on the end of the nose piece and
gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the
opposite side of the nose piece.
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5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should raise slightly.
6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose
piece by hooking the tool under the nose piece and
pulling up. The nose piece should release completely. If the nose piece does not come off, repeat
the procedure on the opposite side.
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7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the
terminal cavity.
* Terminal (1)
* Entry Canal (2)
8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer.
The terminal retainer is a small plastic piece on the
top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the
connector.
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9. The illustration shows a cutaway view of the connector to aid the technician in releasing the
terminal retainer.
10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit
to ensure that the correct release tool is used.
Terminal Repair Procedure
Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair
Kit.
Terminal Replacement Procedure
After the terminal is crimped to the wire, perform the following procedure in order to replace the
terminal.
1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal
into the connector until it locks into place. The new terminal should be even with the other
terminals. Ensure that the terminal is
locked in place by gently pulling on the wire.
3. To assemble the connector, reverse the connector disassembly procedure.
Terminal Position Assurance Locks
Terminal Position Assurance Locks
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Tyco/Amp Connectors (CM 42-Way)
Tyco/AMP Connectors (CM 42-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out.
The CPA is on the wire harness side of connector. 2. Disconnect the connector from the
component.
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3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover
opposite the harness side and prying up. 4. Remove the cover.
5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose
piece forward with your thumb. This will release
the terminal position assurance (TPA).
6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The
release cavities are the 2 center rows of cavities
on one half of the connector.
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7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are
removing, gently pull the wire out of the back of
the connector. Always remember never use force when pulling a terminal out of a connector. See
the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct
release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal.
Tyco/AMP Connectors (Door Module)
Tyco/AMP Connectors (Door Module)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Side view of connector.
View of top of connector.
1. Locate the assist lever and lock on the top of the connector.
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2. While depressing the lock, pull the lever over and past the lock.
3. Disconnect the connector from the component.
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4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to
release the locking tabs. Repeat this procedure for
the other locking tab.
5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector
housing.
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6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang.
See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Tyco/AMP Connectors (Sensor)
Tyco/AMP Connectors (Sensor)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
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2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of
the connector until the terminal release tang access
panel slides over.
3. Ensure that the terminal release tang access panel is in the correct location to access the
terminals. 4. Push the wire side of the terminal that is being removed toward the connector and
hold it in position.
5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located
behind the access panel of the connector and press
down on the terminal while carefully pulling the terminal out of the connector. Always remember
never use force when pulling a terminal out of a connector. If the terminal is difficult to remove,
repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Tyco/AMP Connectors (0.25 Cap)
Tyco/AMP Connectors (0.25 Cap)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component by pressing down on the connector position
assurance (CPA).
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2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool
in the small recess on the side of the connector
and pushing up until the TPA releases from the connector body. The TPA should raise just slightly.
Do not try to remove the TPA.
Important: The TPA on this connector cannot be removed unless the terminals are removed first.
The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the
terminals can be removed. Using excessive force to remove the TPA with the terminals still in the
connector will damage the connector.
3. Repeat the process for the other side of the connector.
4. Ensure that the TPA is in the proper position to remove the terminals.
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5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the
terminal you are removing, gently pull the wire out of the
back of the connector. Always remember never use force when pulling a terminal out of a
connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure
that the correct release tool is used.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the
terminal.
Tyco/AMP Connectors (43-Way)
Tyco/AMP Connectors (43-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
Follow the steps below in order to remove terminals from the connector.
1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body.
2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the
dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once
the locks are unlocked, lift the dress cover off.
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Important: Always use care when removing a terminal position assurance (TPA) in order to avoid
damaging it.
5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the
connector. Gently slide the TPA up to the
released position on both ends.
6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the
terminals by inserting the tool into the terminal release
cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the
terminals by inserting the tool into the terminal release cavity. See the release tool cross reference
in the Reference Guide of the J-38125 to ensure that the correct release tool is used.
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View of the release tool being used for the larger terminals.
View of the release tool being used for the larger terminals.
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View of the release tool being used for the smaller terminals.
7. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Yazaki Connectors (2-Way)
Yazaki Connectors (2-Way)
Tools Required
J-38125 Terminal Repair Kit
Terminal Removal Procedure
1. Disconnect the connector from the component.
2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA)
and pry up.
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3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is
being removed toward the connector and hold it in position.
5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the
terminal to be removed. Ensure that the pointed on
the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it
stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide
of the J-38125 to ensure that the correct release tool is used.
6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector.
Always remember never use force when pulling a
terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure.
Terminal Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Yazaki Connectors (16-Way)
Yazaki Connectors (16-Way)
Tools Required
J-38125 Terminal Repair Kit
Removal Procedure
1. While depressing the lock, pull the two connector halves apart.
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2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards
the face of the connector on both sides of the
connector.
Important: The TPA is fragile and may break if not done carefully.
View of the male half of the connector with female terminals.
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View of the female half of the connector with male terminals.
3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release
cavity. See the release tool cross reference in the
Reference Guide of the J-38125 to ensure that the correct release tool is used.
View of the female half of the connector with male terminals.
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View of the male half of the connector with female terminals.
4. While holding the removal tool in place, gently pull the wire out of the back of the connector.
Always remember never use force when pulling a
terminal out of a connector.
Repair Procedure
Use the appropriate terminal and follow the instructions in the J-38125.
Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate
connector end view.
Circuit Protection - Circuit Breakers
Circuit Protection - Circuit Breakers
A circuit breaker is a protective device that is designed to open the circuit when a current load is in
excess of the rated breaker capacity. If there is a short or other type of overload condition in the
circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types
of circuit breakers are used.
Circuit Breaker
- This type opens when excessive current passes through it for a period of time. It closes again
after a few seconds, and if the cause of the high current is still present, it will open again. The
circuit breaker will continue to cycle open and closed until the condition causing the high current is
removed.
Positive Temperature Coefficient (PTC) Circuit Breaker
- This type greatly increases its resistance when excessive current passes through it. The
excessive current heats the PTC device, as the device heats its resistance increases. Eventually
the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the
PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once
the voltage is removed the circuit breaker will re-close within a second or 2.
Circuit Protection - Fuses
Circuit Protection - Fuses
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The fuse is the most common method of an automotive wiring circuit protection. Whenever there is
an excessive amount of current flowing through a circuit the fusible element will melt and create an
open or incomplete circuit. Fuses are an one time protection device and must be replaced each
time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and
examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a
DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one
of equal current rating.
Circuit Protection - Fusible Links
Circuit Protection - Fusible Links
Fusible link is wire designed to melt and break continuity when excessive current is applied. It is
often located between or near the battery and starter or electrical center. Use a continuity tester or
a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If
broken, it must be replaced with fusible link of the same gage size.
Repairing a Fusible Link
Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient
overload protection.
Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests
and General Diagnostics
Flat Wire Repairs
Flat Wire Repairs
Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists
within the flex wiring harness the complete harness must be replaced.
GMLAN Wiring Repairs
GMLAN Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
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The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working on
GMLAN connectors and terminals.
The tool kit J-38125 contains the following items in order to repair the GMLAN wiring:
* DuraSeal splice sleeves
* A wire stripping tool
* J 38125-8 Crimping Tool (GM P/N 12085115)
* J 38125-5 Ultra Torch Special Tool (GM P/N 12085116)
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
GMLAN Repairs
Important: When making a repair to any GMLAN network, the original wire length after the repair
must be the same length as before the repair. If the network is a twisted pair, the twist must be
maintained after the repair is completed.
GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire
and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher
speeds. For more information on GMLAN, refer to Data Link Communications Description and
Operation.
GMLAN Connector Terminal Repair
Important: A service terminal can be used to replace damaged connector terminals for both high
speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN
high speed system with twisted pair wires, do not untwist the wires more than necessary to make
the repair.
The terminals in the GMLAN system are made of a special metal. This metal provides the
necessary contact integrity for the sensitive, low energy circuits. These terminals are available in
the J-38125. If the individual terminals are damaged on any GMLAN connection, use the
appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs
for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and
General Diagnostics
GMLAN Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5
mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the
J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed
splice.
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You
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must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except coaxial.
* Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent American wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
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8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Heated Oxygen Sensor Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
Notice: Do not solder repairs under any circumstances as this could result in the air reference
being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen
sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In
order for the sensor to function properly it must have a clean air reference. This clean air reference
is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires,
connectors or terminals could result in the obstruction of the air reference and degrade oxygen
sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
* Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and
harness wires must not be damaged in such a way that the wires inside are exposed. This could
provide a path for foreign materials to enter the sensor and cause performance problems.
* Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks,
etc., could block the reference air path through the lead wire.
* Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize
the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal
of the ground wire will also cause poor engine performance.
* To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the
vehicle harness connector.
The engine harness may be repaired using the J-38125.
High Temperature Wiring Repairs
High Temperature Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time
may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical
wiring. When making a repair in a high temperature area observe the following:
* Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any
damaged wire.
* Replace any heat shielding that is removed.
* Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal
Repair kit).
* After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat
source.
Identifying High Temperature Wiring
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Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time
need special considerations when making wiring repairs. Areas that may be exposed to higher
temperatures can be identified by heat resistant materials that are being used in those areas.
These materials may include heat reflective tape, moon tape, and high temperature shrink tubing.
Also conduit and other protective coverings may be used. Because conduit or similar coverings are
used throughout the vehicle regardless of the temperature, it may be necessary for the technician
to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas
of consideration would be any area located near the exhaust manifolds, catalytic converter, and
exhaust pipes.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to
high heat. The kit contains the following items:
* DuraSeal splice sleeves to crimp and seal connections
* High temperature SCT1 shrink tubing to protect the splice sleeves
* A large sampling of common electrical terminals
* The correct crimp tool to attach the terminals to the wires
* The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high
temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage
size as the original wire when repair damage wire. Also replace any reflective tape that you remove
during the repair.
High Temperature Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated
at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm
etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then
encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the order listed. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact.
1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as
little wire off the harness as possible. You may need the extra length of wire in order to change the
location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
4. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent american wire gage
(AWG) size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
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5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced.
Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the
proper color nest of the Splice Crimp Tool. The
crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice
sleeve, and 3 is for the yellow splice sleeve.
8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop.
10. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat
barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
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13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the
heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from
the center to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
16. Replace any reflective tape and clips that may have been remove during the repair.
Repairing Damaged Wire Insulation
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged, locate the problem and apply tape around the
wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing
Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and
Inspection/Component Tests and General Diagnostics
SIR/SRS Wiring Repairs
SIR/SRS Wiring Repairs
Tools Required
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS)
requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR/SRS, and the wiring components,
such as connectors and terminals.
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Diagram Information and Instructions > Page 17380
Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system
terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray.
The tool kit J-38125 contains the following items:
* DuraSeal splice sleeves, in order to repair the SIR/SRS wiring
* A special crimping tool
* A heat torch
* An instruction manual
The DuraSeal splice sleeves have the following 2 critical features:
* A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a
sealing adhesive inside.
* A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for
these sensitive, low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
* A large sampling of common electrical terminals
* The correct tools in order to attach the terminals to the wires
* The correct tools in order to remove the terminals from the connectors
SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin)
The terminals in the SIR/SRS system are made with a special plating. This plating provides the
necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS
Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other
terminals for those in the repair kit.
The J-38125 SIR/SRS Terminal Repair Kit contains:
* Various terminated leads for sensing and diagnostic module (SDM) terminal replacement
* Various connector positive assurance (CPA) locks for SIR/SRS connectors
* Base of steering column pigtail connectors part number 12085514
* Yellow vinyl electrical tape
Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the
connector body is available for connectors with more than eight terminals. The terminated leads in
the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when
replacing the connector body.
SIR/SRS Component Wire Pigtail Repair
Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail
is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering
wheel module coil is an example of a pigtail component.
SIR/SRS Wire Repair
Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are
repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and
Inspection/Component Tests and General Diagnostics
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the
same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice
crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the
integrity of the DuraSeal splice sleeves.
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Diagram Information and Instructions > Page 17381
Important: You must perform the following procedures in the listed order. Repeat the procedure if
any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
* Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness
in order to avoid wire insulation damage.
* Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
* Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming
together.
2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to
change the location of a splice.
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices,
harness branches, or connectors.
3. Strip the insulation:
* When adding a length of wire to the existing harness, use the same size wire as the original wire.
* Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gage.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and work
down until achieving a clean strip of the insulation.
* Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
* Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
* If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at
the beginning of the repair procedure for the color
coding of the DuraSeal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position
the DuraSeal splice sleeve in the proper color
nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice
sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve.
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6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the
end of the barrel and the stop. The sleeve has a stop
(3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand
crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.
7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the
handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal
splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
* The tubing will shrink completely as the heat is moved along the insulation.
* A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Connector Position Assurance (CPA)
The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
a connector. CPAs are used in all SIR System connectors and also in some connectors of other
systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA
in place in order to ensure good contact between the mating terminals of a connection.
Terminal Position Assurance (TPA)
The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do not
remove the TPA from the connector body unless you remove a terminal for replacement.
Splicing Copper Wire Using Splice Clips
Splicing Copper Wire Using Splice Clips
Important: When making a splice in an area that may be exposed to moisture use a crimp and seal
splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See:
Testing and Inspection/Component Tests and General Diagnostics
Tools Required
J-38125 Terminal Repair Kit
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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Diagram Information and Instructions > Page 17383
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original (except fusible link).
* The wire insulation must have the same or higher temperature rating.
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.
5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to
determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold
them between thumb and forefinger.
7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place.
* Ensure that the wires extend beyond the clip in each direction.
* Ensure that no insulation is caught under the clip.
8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool
closes.
Ensure that no strands of wire are cut.
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10. Crimp the splice on each end (2).
11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's
instructions for the solder equipment.
12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the
existing wires.
13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another
harness covering. Use a winding motion in order to
cover the first piece of tape.
Splicing Copper Wire Using Splice Sleeves
Splicing Copper Wire Using Splice Sleeves
Tools Required
J-38125 Terminal Repair Kit
Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from
moisture or provide a good electrical connection.
Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and
coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing.
Follow the instructions below in order to splice copper wire using duraseal splice sleeves.
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Diagram Information and Instructions > Page 17385
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the desired wire.
2. Cut the wire.
* Cut as little wire off the harness as possible.
* Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.
3. Select the proper size and type of wire.
* The wire must be of equal or greater size than the original.
* The wires insulation must have the same or higher temperature rating (4).
- Use general purpose insulation for areas that are not subject to high temperatures.
- Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked
polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the
possibility of fuel contact.
4. Strip the insulation.
* Select the correct size opening in the wire stripper or work down from the largest size.
* Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp
and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115)
crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles
slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the
wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop
in the middle of the barrel in order to
prevent the wire from passing through the splice (3).
9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when
released. The crimper handles will not open until
the proper amount of pressure is applied to the splice sleeve.
10. Shrink the insulation around the splice.
* Using the heat torch, apply heat to the crimped area of the barrel.
* Gradually move the heat barrel to the open end of the tubing.
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Diagram Information and Instructions > Page 17386
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is
achieved.
Splicing Inline Harness Diodes
Splicing Inline Harness Diodes
Many vehicle electrical systems use a diode to isolate circuits and protect the components from
voltage spikes. When installing a new diode use the following procedure.
1. Open the harness.
* If the harness is taped, remove the tape.
* To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
* If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow
direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable
soldering tool.
Important: If the diode is located next to a connector terminal remove the terminal(s) from the
connector to prevent damage from the soldering tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not
remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias.
Reference the appropriate Service Data wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some
heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for
the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and
diode attachment points with tape.
9. Tape the diode to the harness or connector using electrical tape.
Splicing Twisted or Shielded Cable
Splicing Twisted or Shielded Cable
Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable
of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and
other applications where low level, sensitive signals must be carried. Follow the instructions below
in order to repair the twisted/shielded cable.
1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap
the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the
splice is made.
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Diagram Information and Instructions > Page 17387
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire.
Staggering the splices by 65 mm (2.5 in) is
recommended.
Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical
contact with the drain wire.
4. Re-assemble the cable.
* Rewrap the conductors with the mylar tape.
* Use caution not to wrap the drain wire in the tape (1).
* Follow the splicing instructions for copper wire and splice the drain wire.
* Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
Wiring Repairs
Wiring Repairs
The Wiring Repairs section contains the following types of wiring repair information. Using these
elements together will make wiring repair faster and easier:
* Testing for Intermittent Conditions and Poor Connections
* Flat Wire Repairs
* GMLAN Wiring Repairs
* High Temperature Wiring Repairs
* Heated Oxygen Sensor Wiring Repairs
* Splicing Copper Wire Using Splice Clips
* Splicing Copper Wire Using Splice Sleeves
* Splicing Twisted or Shielded Cable
* Splicing Inline Harness Diodes
* SIR/SRS Wiring Repairs
US English/Metric Conversion
US English/Metric Conversion
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Diagram Information and Instructions > Page 17388
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Diagram Information and Instructions > Page 17389
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Diagram Information and Instructions > Page 17390
Wiper Motor: Connector Views
Component Connector End Views - Continued
Rear Window Wiper Motor
Windshield Wiper Motor
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Diagram Information and Instructions > Page 17391
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair
> Air Inlet Grille Panel Replacement
Wiper Motor: Service and Repair Air Inlet Grille Panel Replacement
Air Inlet Grille Panel Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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> Air Inlet Grille Panel Replacement > Page 17394
Wiper Motor: Service and Repair Wiper Motor Module Grommet Replacement
Wiper Motor Module Grommet Replacement
Removal Procedure
1. Remove the front wiper motor. 2. Remove the grommets and the bushings from the module.
Installation Procedure
Important: The metal bushing inserts need to be installed with the flat side underneath the module
bolts.
1. Install the grommets and the bushings to the module. 2. Install the front wiper motor.
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> Air Inlet Grille Panel Replacement > Page 17395
Wiper Motor: Service and Repair Windshield Wiper Motor Replacement
Windshield Wiper Motor Replacement
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> Air Inlet Grille Panel Replacement > Page 17396
Wiper Motor: Service and Repair Liftgate Wiper Motor Replacement
Liftgate Wiper Motor Replacement
Removal Procedure
1. Remove the rear wiper arm. 2. Remove the liftgate trim panel.
3. Remove the rear wiper motor bolts. 4. Remove the motor by sliding the pivot shaft out of the rear
window grommet. 5. Disconnect the electrical connector.
Installation Procedure
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> Air Inlet Grille Panel Replacement > Page 17397
1. Connect the electrical connector. 2. Install the rear wiper motor through the rear window
grommet.
Notice: Refer to Fastener Notice.
3. Install the wiper motor bolts.
Tighten the bolts to 7 N.m (62 lb in).
4. Install the liftgate trim panel. 5. Install the wiper motor module.
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> Air Inlet Grille Panel Replacement > Page 17398
Wiper Motor: Service and Repair Windshield Wiper System Module Replacement
Windshield Wiper System Module Replacement
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> Air Inlet Grille Panel Replacement > Page 17399
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Wiper Relay: Locations
Electrical Center Identification Views
Fuse Block - Underhood Label
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Instrument Panel/Center Console Component Views
Steering Column Components
1 - Turn Signal / Multifunction Switch 2 - Inflatable Restraint Steering Wheel Module Coil 3 Windshield Wiper / Washer Switch 4 - Theft Deterent Module 5 - Electric Power Steering (EPS)
Motor 6 - Electric Power Steering (EPS) Module (PSCM) 7 - Ignition Lock Solenoid 8 - Ignition
Switch
Instrument Panel and Console Components 1 of 3
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
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17406
1 - Ambient Light Sensor 2 - Instrument Panel Cluster (IPC) 3 - Driver Information Center (DIC)
Switch 4 - Hazard Switch 5 - Inflatable Restraint Passenger Air Bag ON/OFF Indicator 6 - Rear
Wiper/Washer/Fog Lamp Switch (T96) 7 - Radio 8 - HVAC Control Module 9 - Heated Seat Switch
- Driver, Heated Seat Switch - Front Passenger 10 - Power Window Switch - Main 11 - Traction
Control Switch (TCS) 12 - Dimmer Switch 13 - Outside Rearview Mirror Switch
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17407
Wiper Switch: Diagrams
Component Connector End Views - Continued
Rear Wiper/Washer/Fog Lamp Switch
Windshield Wiper/Washer Switch
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17408
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair
> Rear Window Wiper and Washer Switch Replacement
Wiper Switch: Service and Repair Rear Window Wiper and Washer Switch Replacement
Rear Window Wiper and Washer Switch Replacement
Chevrolet Equinox Awd Workshop Manual (V6-3.4L (2008))
Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair
> Rear Window Wiper and Washer Switch Replacement > Page 17411
Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement
Windshield Wiper and Washer Switch Replacement
Removal Procedure
1. Remove the steering column trim covers. 2. Disconnect the wipers/washer switch connector.
3. Depress the locking tabs and remove the wiper/washer switch.
Installation Procedure
1. Install the wipers/washer switch to the steering column.
Ensure the locking tabs are fully engaged.